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Old 09-20-2013, 12:37 PM   #1
kernal
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Default Think I have a charger problem

Cart has been operating normally. After using it yesterday, I plugged in the charger, checked that the amps jumped up and went in the house. This morning I came out to discover the charger still running AND still at 18 amps. Unplugged the charger. Batteries were very hot although I could hold my hand on them. A little bit of the electrolyte had leaked out of some of the caps. All batteries still had sufficient water in them. Let them rest for 6 hours then drove around the block. Cart operated normally in every way. After the drive the battery pack voltage was 38.1 and each battery was 6.3-6.4.
I bought the batteries (t-105s) new in July 09 and they have had meticulous care. The charger pictured below came with the cart new in 2000 and has worked perfectly until last night.

So the problem is the charger didn't shut off and apparently wasn't sensing pack voltage as the amps never tapered off either. At the moment I am blaming the charger but don't know how to trouble shoot it.

edit: My DVM meter has a new battery
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Old 09-20-2013, 12:40 PM   #2
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Default Re: Think I have a charger problem

Thanks to JohnnyB I'll offer this. Plug the cart on to the cart and plug into house current. Unplug charger from cart. If its still humming and showing amps. The problem lies with the charger.
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Old 09-20-2013, 12:47 PM   #3
kernal
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Default Re: Think I have a charger problem

OK, so starting with the charger not plugged into wall or cart. I plugged charger into cart--heard a click. Then I plugged charger into wall. Charger started to hum and amps jumped up to ~18. Unplugged charger from cart and charger shut off. Did I understand you correctly?
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Old 09-20-2013, 06:48 PM   #4
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Default Re: Think I have a charger problem

That's the same charger I have and yours seems to be working the same as mine, except it appears that the current is not tapering back correctly. Is there any chance that the ammeter is sticking at 18 amps? You could try tapping on the meter after a couple hours of charging to see if the needle is stuck. What is the on charge voltage after what seems to be the proper amount of charge time? (Should be 44-46 volts just prior to shutdown). Also, you could double check the individual battery voltages to make sure one of them isn't sick. Hopefully johnnieb will be along soon to the rescue. Good luck, hopefully it's something simple! - RAY

Last edited by bigstik40; 09-20-2013 at 06:59 PM.. Reason: add info.
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Old 09-21-2013, 05:13 AM   #5
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Default Re: Think I have a charger problem

Quote:
Originally Posted by kernal View Post
OK, so starting with the charger not plugged into wall or cart. I plugged charger into cart--heard a click. Then I plugged charger into wall. Charger started to hum and amps jumped up to ~18. Unplugged charger from cart and charger shut off. Did I understand you correctly?
Yes, you did it correctly. What's the pack voltage while on charge after 12 hrs on charge? What is it after 12 hours rest after shutting off charger?
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Old 09-21-2013, 07:11 AM   #6
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Default Re: Think I have a charger problem

Quote:
Originally Posted by MuckSavage View Post
Thanks to JohnnyB I'll offer this. Plug the cart on to the cart and plug into house current. Unplug charger from cart. If its still humming and showing amps. The problem lies with the charger.
Slight correction.
Leave the "and showing amps" part off the statement.

It is unlikely, but possible, for amps to show on the charger's ammeter when the charger stays on after being unplugged from cart.

The two quick GO/NO-GO control board test are:

1. Turning ON: Plug charger into cart without plugging into AC Power.
If you hear the relay in the charger click, it is GO.
If you don't hear the click, further troubleshooting is needed.

2. Turning OFF: Unplug charger from cart while charger is charging cart.
If charger's transformer stops humming, it is GO.
If it continues to hum, further troubleshooting is needed.
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Old 09-21-2013, 07:27 AM   #7
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Default Re: Think I have a charger problem

Quote:
Originally Posted by kernal View Post
OK, so starting with the charger not plugged into wall or cart. I plugged charger into cart--heard a click. Then I plugged charger into wall. Charger started to hum and amps jumped up to ~18. Unplugged charger from cart and charger shut off. Did I understand you correctly?
The charger's control board appears to be working correctly.

The reason the amps are not tapering off and the charger is staying on is because the battery pack's On-Charge voltage isn't climbing above about 42V. It is more likely a battery problem than a charger problem, but could be either.

Check the On-Charge voltage of the battery pack while the charger is putting out ~18A and the the individual battery's On-Charge voltages at ~18A.

The individual voltages ought to be roughly 1/6 of whatever the pack voltage is.

Also, if possible try a different charger on your cart or your charger on a different cart.

Last edited by JohnnieB; 09-21-2013 at 07:32 AM.. Reason: Added info
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Old 09-21-2013, 07:34 AM   #8
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Default Re: Think I have a charger problem

The two quick GO/NO-GO control board test are:

1. Turning ON: Plug charger into cart without plugging into AC Power.
If you hear the relay in the charger click, it is GO.
If you don't hear the click, further troubleshooting is needed.

2. Turning OFF: Unplug charger from AC power while charger is charging cart.
If charger's transformer stops humming, it is GO.
If it continues to hum, further troubleshooting is needed.[/QUOTE]

Thanks for taking the time to consider my problem.

The charger passed both of these tests. Clicks when plugged into cart and humming stops when AC power is shut off.
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Old 09-21-2013, 07:43 AM   #9
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Default Re: Think I have a charger problem

Quote:
Originally Posted by JohnnieB View Post

2. Turning OFF: Unplug charger from AC power while charger is charging cart.
If charger's transformer stops humming, it is GO.
If it continues to hum, further troubleshooting is needed.
How would the transformer hum if it's unplugged from AC?
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Old 09-21-2013, 07:43 AM   #10
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Default Re: Think I have a charger problem

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Originally Posted by JohnnieB View Post
The charger's control board appears to be working correctly.

The reason the amps are not tapering off and the charger is staying on is because the battery pack's On-Charge voltage isn't climbing above about 42V. It is more likely a battery problem than a charger problem, but could be either.

Check the On-Charge voltage of the battery pack while the charger is putting out ~18A and the the individual battery's On-Charge voltages at ~18A.

The individual voltages ought to be roughly 1/6 of whatever the pack voltage is.

Also, if possible try a different charger on your cart or your charger on a different cart.
Pack resting voltage is 38.0. Plugged in charger. Pack voltage is 41 and rising slowly. Each battery is 6.7--6.9 and rising slowly.
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