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Old 11-18-2012, 09:55 AM   #1
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Default Need 20484 Charger help

I have the following charger:

EZ GO Textron 36V Total Charge Model 20484 Listed 20L4, serial # 68728, the circuit board is 27417 G01.

Heres what I have.

39V at the plug, no current draw on a battery bank that reads 33V. I've checked both sides of the ammeter and I have 39V on both connections. That tells me the shunt in the meter has continuity. Even with that continuity is it possible the meter is still bad? Can I just jumper the meter out of the circuit and check the output with a DC amp clamp?

Thanks for your time.
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Old 11-18-2012, 04:56 PM   #2
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Default Re: Need 20484 Charger help

If you have 39V at the plug and 33V at the battery pack, there is an open somewhere in the charge loop.

Yes, the meter can be bad while the meter shunt is still has continuity.

Is this the type charger you have?
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Old 11-20-2012, 12:59 PM   #3
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Default Re: Need 20484 Charger help

Yes, that's the unit I have.

Let me clarify, I used a battery pack that read 33V before I connected the charger, I connected the charger and I get 39V at the battery pack.

Shouldn't I be getting on the order of 42V out of the charger?

I'm going to jumper the meter today and see what I get.

Thanks for your time and quick response.

Paul
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Old 11-20-2012, 01:41 PM   #4
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Default Re: Need 20484 Charger help

The batteries are/were horribly discharged, so it is going to take hours to charge them, if they can be charged.

The pack voltage starts at wherever it starts at and climbs until it reaches a predetermined voltage in the 44-465V range, which shuts off the charger.

How long it take to get there depends on hopw low the batterie were and the condition they are in.

Climbing ti 42V is usually fairly quick (an hour or so) and from there to shut off may take 6-10 hours.

With batteries discharged down to about 70% State of Charge, 4-6 hours total charge time is typical, with good batteries.
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Old 11-21-2012, 08:57 AM   #5
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Default Re: Need 20484 Charger help

Well we've determined the charger is not putting out any voltage, it buzz'z when turned on but the voltage we're reading is the battery pack not the charger. We've by passed the board, diodes are good, when checking the transformer we get on the order of .03 ohms on both winding's but I don't know what it should read but I would think something like a dead short. We have no way of testing the capacitor.

I'm at a loss
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Old 11-21-2012, 09:53 AM   #6
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Default Re: Need 20484 Charger help

Here is how to check both transformer and capacitor.

You'll have to (or at least you should have to) jumper the relay to get the charger to turn on when it's not connected to cart.

If the capacitor is bad, a Motor Run capacitor from you local electrical supply will work. (Motor run, rather than motor start, and the same MFD)

Yell if you need more help.
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Old 05-22-2014, 11:06 AM   #7
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Default Re: Need 20484 Charger help

I need help with a my charger that is the same as the model state, 20484. I have bypassed the board to test the output and I get 40~42 V DC at the end of the plug. However, when I charge it is like it cuts out after about 20 minutes of use and doesn't completely charge...any suggestions on where to start looking?
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Old 05-22-2014, 11:54 AM   #8
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Default Re: Need 20484 Charger help

Quote:
Originally Posted by cequil32 View Post
I need help with a my charger that is the same as the model state, 20484. I have bypassed the board to test the output and I get 40~42 V DC at the end of the plug. However, when I charge it is like it cuts out after about 20 minutes of use and doesn't completely charge...any suggestions on where to start looking?
If you are only getting 40-42 volts out when it is not connected to the battery pack, you are only getting about half of what the unloaded voltage should be, so I suspect you have a bad diode.

Replace them both, 1n1184 will work.

While you've got it open and the diodes disconnected, check the voltage out of the transformer with and without the capacitor connected as explained in post above.
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Old 05-23-2014, 07:37 AM   #9
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Default Re: Need 20484 Charger help

If he bypassed the board, what would cause it to cut out after 20 minutes? I'm assuming it's not a breaker tripping or he would have mentioned it.
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Old 05-23-2014, 08:29 AM   #10
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Default Re: Need 20484 Charger help

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Originally Posted by yurtle View Post
If he bypassed the board, what would cause it to cut out after 20 minutes? I'm assuming it's not a breaker tripping or he would have mentioned it.
It boils down to what is meant by "it acts like it cuts out", so cutting out could more perception than fact.

Perhaps the ammeter reading drops so low after about 20 minutes that it looks like the needle is on zero.

The output of the charger is a full-wave rectifier type with a center-tapped transformer whose AC voltage is from about 60VAC up to around 90VAC depending on how much boost the capacitor is providing. After being rectified by the diodes the DC voltage reading would depend on how the DVM used processed DC pulsating at 120 HZ, but it would at least be as high as the AC input to the diodes. An output of 40-42 VDC, means an input of 40-42 VAC to the rectifier section, or one half of the center tapped secondary.

Since the DC output is lower than 45VDC, the capacitor's Farad value may also be a bit off the proper value.

If I was repairing this charger, I'd first get the AC voltage out of the transformer up to 90VAC with the proper value capacitor installed, then replace the diodes and finally replace the control board if needed.

If the transformer was bad (Does not put out 60VAC without capacitor installed), I'd replace the charger with a DPI Accusense.
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