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Old 09-17-2015, 08:51 PM   #1
bart98stang
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Default I'm thinking I have a bad charger

Greetings all. My name is Mike and I'm a noob who just registered. I'm having a problem charging my 2002 g19 and I've been searching through this forum for the past few days.

I just bought my car from a EV dealer in Va Beach, Va. who stated that the batteries are only a year old. They are Pride Power GC220. I've looked for a date code and cannot find anything, however it does have GC61200A31121 etched on all of the batteries if that helps. The charger that came with the car doesn't have a manufacture name but has a model number of SCR481717. I'm a Interior Communications electrician in the Navy which I deal mostly with electronic navigation, telephone systems, alarm/safety/warning circuits so I do have electrical background but never with golf carts and chargers. Before I bought the cart I checked over all the connections and they looked really clean with no corrosion and no loose connectors. I also had the guy plug in the charger for about 30 minutes to make sure that it did charge the batteries

When I got home I placed the car in tow mode then plugged in the charger into the car then into the AC outlet and all the leds lit up during the diagnostics test then the "charger on" and "incomplete" led's stayed lit like they are supposed to. After a few hours the abnormal cycle led lit up. I've read up on the abnormal cycle led and it was said to take readings on the pack, then each individual battery then do a specific gravity test on each cell on all of the batteries. I haven't done that yet because on a hunch I unplugged the charger plug from the car and I read 48.23 VDC right at the plug. I plugged in back in and then lifted up the seat and read the back of the receptacle and it read 47.09 VDC. I then unplugged the charger from the car then the AC source and I took the cover off. It was pretty dusty and has some spider webs but nothing was burnt or loose and both the AC source cable and the DC output cable had good continuity. I cleaned it then put it back together and plugged in back in and after a few minutes to let it settle down and checked the plug and receptacle again and still had the same readings as above. The highest I have read of the pack before it went into abnormal cycle was 46.85 VDC. If I'm not mistaken shouldn't the output of the charger probably be around 50-52 VDC? When I get off of work tomorrow I'll charge the batteries again and then remeasure the pack then read each battery individually while still connected in series then with all cables removed. Thanks in advance for your guidance and advice.
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Old 09-18-2015, 03:32 AM   #2
cgtech
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Default Re: I'm thinking I have a bad charger

You have a charger made for yamaha by "motor appliance corporation - MAC", it was an advanced "5-stage" charger in its day. It has been a good charger. Used from 'about' 1995 until 2006. Its " Achilles heel" was the DC fuse at the bottom of the front panel (with a sight window), that was victim to failures from high heat. Newer models were equipped with a internal fuse and that problem was solved. OEM equipment was pretty reliable in it, aftermarket control boards were questionable in their reliability. The original board would shut the charger off pretty quickly when unplugged (hard to read voltages on a charger that is off). The "on charge" voltage should be reaching around 60-62v dc when nearing shut-off at end of charge cycle. (aftermarket control boards are a gamble, they were not consistant). Check the pins in the charger plug handle. And check the sockets on the receptacle (they are common to get "gunked-up or melted" with age). I have test procedures for the charger, as needed, check this other stuff first. My best suggestions are to use only OEM parts to fix the charge plugs (from yamaha or nabson). If the charge control board in the charger is found to be bad , a new DPI is the best bet (the real OEM board is as much as a new DPI charger, also made in USA). Both are very good chargers with modern charge theories, but the DPI has 2 main advantages the OEM didnt, "float charge" to keep it topped-off all the time while stored, and, user-selectable modes for different brands/types of batteries.
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Old 09-18-2015, 02:30 PM   #3
bart98stang
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Default Re: I'm thinking I have a bad charger

Thank you very much. I failed to mention yesterday when I wrote the op that I did take the plug apart and visually inspected it and it was clean with no sign of overheating and no corrosion. I did check the receptacle and it was also clean with no sign of overheating and good continuity between the front and back and open between the + and -. Next I disconnected every cable and lightly sanded all terminals with emery cloth. I connected everything back together and plugged the charger back in. The charger kicked on and the voltage of the pack climbed steady but stopped at 48.11VDC. Here are the other readings I took:

Pack 48.11VDC
Charger plug disconnected 49.13VDC
Receptacle with charger plugged in 48.20
Battery 1 7.98VDC
Battery 2 8.17VDC
Battery 3 7.94VDC
Battery 4 7.93VDC
Battery 5 8.02VDC
Battery 6 8.06VDC
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Old 09-18-2015, 06:17 PM   #4
bart98stang
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Default Re: I'm thinking I have a bad charger

CG would you be able to send me the charger troubleshooting procedure or direct me a link? Thanks.
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Old 09-18-2015, 07:55 PM   #5
bart98stang
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Default Re: I'm thinking I have a bad charger

Well i might have found the problem. I should've noticed this first. its a 48v car and there is 6 6vdc batteries vice 6 8vdc batteries. I'm getting in touch with the owner of the dealership now.
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Old 09-18-2015, 08:14 PM   #6
jericho
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Default Re: I'm thinking I have a bad charger

yep that could be your problem.
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Old 09-18-2015, 09:16 PM   #7
bart98stang
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Default Re: I'm thinking I have a bad charger

Quote:
Originally Posted by jericho View Post
yep that could be your problem.
Yes sir I agree!!
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Old 09-18-2015, 10:08 PM   #8
cgtech
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Default Re: I'm thinking I have a bad charger

Uh, yeah, i think we can stop searching, for now.......
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Old 12-11-2015, 02:10 PM   #9
KGT
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Default Re: I'm thinking I have a bad charger

I am interested in the trouble shooting guide for the SCR481717 Yamaha charger. Thanks in advance for sharing the information.
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Old 12-11-2015, 07:48 PM   #10
cgtech
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Default Re: I'm thinking I have a bad charger

Here ya go.
Attached Files
File Type: pdf scr.pdf (205.2 KB, 0 views)
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