lifted club cars - lifted ezgo
Home FAQDonate Who's Online
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Electric EZGO
Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



Post New Thread  Reply
 
Thread Tools Display Modes
Old 07-12-2016, 12:03 PM   #1
KRAZYMATT
Gone Wild
Club Car
 
Join Date: Aug 2010
Location: Central Florida
Posts: 1,506
Default Charging Problems W/ Total Charge 1

Having some issues with EZGO Automatic Battery Charger "Total Charge 1" (the green face charger). Coworker got in the cart and pulled away with charger still plugged in. Charger fell off shelf about 5' high. Unit wont charge when plugged into cart (cart charge read 33.9vdc on multimeter). I opened it up, fuse is good, breaker is closed/ not tripped. I got 120 into im guessing what is called the relay board. I get nothing out of it weather the cart is plugged into it or not. Ive checked the voltage at the charge port on the cart and read a battery charge of 33.9 volts. I took the yellow wire (120 out from relay board) off the mechanical timer and just brought the 120 (from the line-in after the fuse) right up to the timer (bypassing the relay board) and the charger turns on with the timer and output at the charge plug read 41vdc with a meter. Is there a way to test the board? Im guessing the board is supposed to sense a load (cart being plugged in) before it will allow the charger to come on? What is the cut in voltage and cutout voltage the board looks for? It is working now with the relay board out of the loop but im afraid its just going full output and do not want to ruin a fairly new (6 month old) set of batteries. The cart was ran down to 33vdc and I charged them up to around 36vdc with the charge board bypassed. I did not check the diodes or the capacitor. When the charger is plugged in to the cart should the red and black wires going to the relay board read the same level charge as the cart batteries?
Attached Images
File Type: jpg IMG_8712.jpg (93.4 KB, 0 views)
File Type: jpg IMG_8715.jpg (78.0 KB, 0 views)
File Type: jpg IMG_8716.jpg (84.8 KB, 0 views)
File Type: jpg 127362d1447006787-total-charge-20484-wiring-diagram-total-charge-green-face-parts-pg-2.jpg (101.6 KB, 0 views)
Attached Files
File Type: pdf 127360d1447006145-total-charge-20484-wiring-diagram-total-charge-wiring.pdf (104.9 KB, 0 views)
KRAZYMATT is offline   Reply With Quote
Alt Today
BGW

Golf car forum Sponsored Links

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum
   
Old 07-13-2016, 07:48 AM   #2
HiTechRedNeck
Gone Wild
 
Join Date: Aug 2014
Location: Duncan Corners
Posts: 905
Default Re: Charging Problems W/ Total Charge 1

Get DPI charger.
Batts will last longer, Life will be easier ( plug cart in -- charger handles the rest)
HiTechRedNeck is offline   Reply With Quote
Old 07-13-2016, 09:12 AM   #3
JohnnieB
Techno-Nerd
 
JohnnieB's Avatar
E-Z-GO
 
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
Default Re: Charging Problems W/ Total Charge 1

You won't hurt the batteries by charging with the relay bypassed as long as you don't let the charger run for more than about 16 hours.

The "control" board does not control the battery charging profile, All the control board does is connect and disconnect AC power to the transformer primary. The battery charging profile is built into the ferroresonant transformer and capacitor pair.

The cart's battery pack voltage is what powers up the control board and energizes the relay initially. The pack voltage has to be about 28V or so get the relay to close and power up the charger. The voltage between the red and black wires on the control board should be the same as the pack voltage, or there is excessive resistance in the battery sensing circuit.

When the on-Charge voltage reaches about 45V, the control board disconnects AC power from the transformer. If 45V is reached in about 12 hours, the electro-mechanical timer times out and disconnects AC power from the transformer.

In a nutshell, the battery charger circuit is the transformer, capacitor and diodes, while the control board is a semi-smart on/off switch.
JohnnieB is offline   Reply With Quote
Old 07-13-2016, 10:18 AM   #4
KRAZYMATT
Gone Wild
Club Car
 
Join Date: Aug 2010
Location: Central Florida
Posts: 1,506
Default Re: Charging Problems W/ Total Charge 1

Thanks JohnnieB! So as long as its working now with the control board bypassed I should be ok. The mechanical timer is still controlling the length of the charge cycle.
KRAZYMATT is offline   Reply With Quote
Reply
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Electric EZGO




Similar Threads
Thread Forum
Ez go total charge iii problems Electric EZGO
Textron Total Charge Not Charging Electric EZGO
Total Charge III problems Electric EZGO
Total Charge III Charger problems, need schematic Electric EZGO
total charge IV only charging for an hour?? Electric EZGO


All times are GMT -5. The time now is 11:58 PM.


Club Car Electric | EZGO Electric | Lifted Golf Carts | Gas EZGO | Used Golf Carts and Parts

Powered by vBulletin® Version 3.8.9
Copyright ©2000 - 2024, vBulletin Solutions, Inc.
This Website and forum is the property of Buggiesgonewild.com. No material may be taken or duplicated in part or full without prior written consent of the owners of buggiesgonewild.com. © 2006-2017 Buggiesgonewild.com. All rights reserved.