power wise charger blowing the 50 amp fuse

jetfan1950

Friends charger is sparking and blowing the fuse just as he plugs it into the cart (95 txt). My power wise charger works fine with his cart. We followed the you tube video to test and continuity of 3 cables is fine but we can't check the relay board(new style board) as the fuse will blow when we plug it in. The diode checks good (open to the chassis ground). This is a new diode. The original diode was bad...it appeared that both contacts were blown off the board. We have not been able to check the capacitor yet as the wires are rusted to the contacts. We have them soaking in liquid wrench. Any suggestions while we wait for another fuse to arrive?

BGW

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cgtech

Double check both sides of the diodes (has 3 screw terminals), both directions. Use the diode test setting "-|>|-" on your meter, it is also the one that beeps. Should get ~.470 ohm in one direction, infiniti (no connection) other direction. Transformer could also be bad. Bad capacitor will not cause blown fuse. Relay & control board will not cause blown fuse.

cgtech

Oh, wait, you have the older charger with the "round tube" fuse on the AC side. My mistake. That sounds like a shorted transformer. It blows as soon as its plugged into the wall and not the cart?

jetfan1950

No it blows when plugged into the cart. The fuse is the flat black fuse.

radioman

If it is blowing a 50 amp fuse on the AC side something should smoke beside the fuse. That would be 6000 watts.

HiTechRedNeck

i agree with cgtech --- re check diodes

remac

Which flat black fuse are you talking about?
Is the fuse on the charger or is it on the cart?

My cart has a flat black 50Amp fuse on the first battery
where the charging line connects to the batteries.
That is there to protect the charging line from a short.
If this is the fuse that is blowing then you have a short
in your charger or in the connector or cable.

radioman

I think you have solved part of the mystery. The fuse that is blowing is on the golf cart battery connection in the charger lead. There is no AC fuse of that amperage rating in the charger. Also I don't think you can check diodes from the device to the charger metal frame. Whatever is causing the fuse to blow should be easy to find with and ohm meter set to R x 1 scale. To isolate the problem I would disconnect the diodes and check them on the low resistance for a short on the R x 1 scale and the same across the connector pins that mate with the golf cart. A 50 amp fuse on the AC side in the charger would trip the breaker in the power panel. The most likely problem would be one or more shorted diodes (0 ohms).

MaReed27

The 50 amp fuse is inside the battery charger and is attached to the cord that plugs into the cart

radioman

Some confusion here. The fuse is apparently on the DC output of the charger. Does it blow when you plug charger cable into cart without the charger plugged into AC or does the charger have to be on?