MAC Charger Says Incomplete

mbweido3 · 03-30-2009, 10:26 AM

I have a G22 Yamaha cart with a 48v MAC SCR Charger. I did not use for several months upon returning, I had no power and the charger would not turn on or self test. After charging the batteries to approximately 47 volts the charger would then self test but go to incomplete after the test.

I have done the following:
1. Replaced relay due to melted box and chard black wire coming from circuit breaker.
2. Replaced circuit breaker because it didnt have continuity.
3. Have 120 +/- volts from cord, into circuit breaker, out of circuit breaker and A and B terminals of relay.
4. When the DC plug is plugged into the cart it will self test even without being plugged into AC (SCR manual says this means DC side is OK).

What should I test from here, could it be the circuit board. Any suggestions or help would greatly be appreciated.

smallblock450sl · 03-30-2009, 06:53 PM

Many times after "force charging" the battery set, must be 44 volts or more (sounds like you did that), the first time the mac starts charging (in about 2 hours) it will stop and show abnormal. We useually just unplug and replug and the next morning its fully charged. How long did the batteries sit without being charged and how old are the? Dave

mbweido3 · 03-31-2009, 08:10 AM

Dave,
Not exactly sure how long they where uncharged but probably two months. The batteries are Trojan 875 and will be 2 years old in June.
I took them to a local battery shop to have them charged because I didnt have anything that would charge them. They said the batteries were still good and got them charged to about 49v. The charger will self test and then it goes to incompete but will never turn on (humm). Bobby

mbweido3 · 03-31-2009, 07:19 PM

Should there be continuity through the varistor? There is continuity through each side of varistor but not throught the varistor itself.

rusty · 04-01-2009, 11:55 PM

Hello mbweido3 and Welcome to the forum.

mbweido3 · 04-02-2009, 08:04 AM

Thanks Rusty. Do you know if you should have continuity through the varistor?

mbweido3 · 04-06-2009, 01:09 PM

I was able to isolate and solve my problem by unplugging the 4 pin connector that plugs into the control board and running a jump wire from the connectors two wires, which by-passed the control board and the charger turned on and charged. So I am ordering a new control board. Thanks

03-30-2009, 10:26 AM	#1
mbweido3 Not Yet Wild Join Date: Mar 2009 Posts: 5	MAC Charger Says Incomplete I have a G22 Yamaha cart with a 48v MAC SCR Charger. I did not use for several months upon returning, I had no power and the charger would not turn on or self test. After charging the batteries to approximately 47 volts the charger would then self test but go to incomplete after the test. I have done the following: 1. Replaced relay due to melted box and chard black wire coming from circuit breaker. 2. Replaced circuit breaker because it didnt have continuity. 3. Have 120 +/- volts from cord, into circuit breaker, out of circuit breaker and A and B terminals of relay. 4. When the DC plug is plugged into the cart it will self test even without being plugged into AC (SCR manual says this means DC side is OK). What should I test from here, could it be the circuit board. Any suggestions or help would greatly be appreciated.
mbweido3 Not Yet Wild Join Date: Mar 2009 Posts: 5

03-30-2009, 06:53 PM	#2
smallblock450sl Sometime's............ Join Date: Oct 2007 Location: Tacoma Washington Posts: 11,874	Re: MAC Charger Says Incomplete Many times after "force charging" the battery set, must be 44 volts or more (sounds like you did that), the first time the mac starts charging (in about 2 hours) it will stop and show abnormal. We useually just unplug and replug and the next morning its fully charged. How long did the batteries sit without being charged and how old are the? Dave

03-31-2009, 08:10 AM	#3
mbweido3 Not Yet Wild Join Date: Mar 2009 Posts: 5	Re: MAC Charger Says Incomplete Dave, Not exactly sure how long they where uncharged but probably two months. The batteries are Trojan 875 and will be 2 years old in June. I took them to a local battery shop to have them charged because I didnt have anything that would charge them. They said the batteries were still good and got them charged to about 49v. The charger will self test and then it goes to incompete but will never turn on (humm). Bobby
mbweido3 Not Yet Wild Join Date: Mar 2009 Posts: 5

03-31-2009, 07:19 PM	#4
mbweido3 Not Yet Wild Join Date: Mar 2009 Posts: 5	Re: MAC Charger Says Incomplete Should there be continuity through the varistor? There is continuity through each side of varistor but not throught the varistor itself.
mbweido3 Not Yet Wild Join Date: Mar 2009 Posts: 5

04-01-2009, 11:55 PM	#5
rusty Golf Cart Photographer Join Date: Jan 2007 Location: Wichita Falls Texas - My Ride 2010 Club Car Posts: 6,236	Re: MAC Charger Says Incomplete Hello mbweido3 and Welcome to the forum.

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04-02-2009, 08:04 AM	#6
mbweido3 Not Yet Wild Join Date: Mar 2009 Posts: 5	Re: MAC Charger Says Incomplete Thanks Rusty. Do you know if you should have continuity through the varistor?
mbweido3 Not Yet Wild Join Date: Mar 2009 Posts: 5

04-06-2009, 01:09 PM	#7
mbweido3 Not Yet Wild Join Date: Mar 2009 Posts: 5	Re: MAC Charger Says Incomplete I was able to isolate and solve my problem by unplugging the 4 pin connector that plugs into the control board and running a jump wire from the connectors two wires, which by-passed the control board and the charger turned on and charged. So I am ordering a new control board. Thanks
mbweido3 Not Yet Wild Join Date: Mar 2009 Posts: 5

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