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Old 07-10-2013, 12:09 PM   #1
thetoddjohnson
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Default 48V charger keeps tripping 15A breaker

Hi. I wanted to lengthen the cord that goes from the charger to the cart so that I could leave the charger in the garage (protected from the elements) while charging the cart outside. I figured that an 8AWG cable would be sufficient for a 25' run.

Before purchasing the cable I wanted to see if splicing would be involved, or if I'd be able to run a cable that thick through the same route that the existing 12AWG cable runs. So I went through the exercise of opening the charger and removing the current cable. Confident that I'd be able to use 8AWG I reinstalled the 12AWG cable and planned to purchase 8AWG next time I swung by an electrical supply store.

To the best of my knowledge I reassembled the charger exactly as it was before I did my investigation. The next time I plugged the charger in the lights flashed as usual, the charger kicked on, and I went in the house. In the morning the "abnormal cycle" light was illuminated. I figured that I must have done something wrong, so I opened the charger again and verified that everything was connected properly. Now if I plug the charger into the cart the lights will flash, the charger will kick on, then after 15 or 20 seconds the 15A breaker on the front of the charger will trip.

After on BGW I found a few posts that indicate once one of those breakers trips it tends to trip, so I figured perhaps the breaker was bad. I replaced the breaker, but the problem persists.

So, either I somehow damaged the charger, or there is a bizarre coincidence that it just happened to have problems after I was tinkering with it.

I have two G29 carts and 2 identical chargers. I do not believe this problem is related to the quality of the batteries, because the problem exists regardless of which cart I'm trying to charge, and also both carts will successfully charge with the other charger.

Any ideas on what to do next with the "tripping" charger?

Thanks,

TJ
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Old 07-10-2013, 12:22 PM   #2
gornoman
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Default Re: 48V charger keeps tripping 15A breaker

First thing to do is check the polarity of the charge plug and the cart. Make sure positive goes to positive....
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Old 07-10-2013, 02:11 PM   #3
thetoddjohnson
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Default Re: 48V charger keeps tripping 15A breaker

Yeah, that was what I was checking when I took it back apart. It is hooked up correctly.

Any other thoughts?

Thanks,

TJ
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Old 07-10-2013, 11:12 PM   #4
cgtech
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Default Re: 48V charger keeps tripping 15A breaker

if the dc charge wires had somehow become flipped on a MAC charger, the internal fuse would have blown. at that point the lights would no longer light up when plugged into the cart, i dont think this is the problem. If you connected the AC lines up incorrectly, you may have ruined the charger board. if you are handy with a multimeter, and are familiar with identifying parts i can help you with these MAC chargers (i fixed 3 today).
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Old 07-11-2013, 06:37 AM   #5
thetoddjohnson
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Default Re: 48V charger keeps tripping 15A breaker

Cgtech,

I've got a multimeter and would love your help. I never disconnected the AC wires so there is no risk of that being wrong.

In order not to clog up BGW if you want to contact me directly I've got a gmail account with the same username as my BGW account.

Thanks for offering to help,

TJ
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Old 07-11-2013, 06:41 AM   #6
speedgolfer
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Default Re: 48V charger keeps tripping 15A breaker

Charger draw between 9 and 10 amps and then stretching it out another 25 ft makes it draw 11 or 12 and a 15 amp breaker you are only suppose to load it 80 percent so check the size of wire (it will say on it) 14/2 or 12/2 if its is 14/2 it is 15 amp or 12/2 then put 20 amp breaker
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Old 07-11-2013, 08:13 AM   #7
Dave Box
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Default Re: 48V charger keeps tripping 15A breaker

If you lengthened the low voltage cables and now have a problem it would seem logical to reinstall the original cables to see if the problem is resolved. As a spec guess I would say that additional resistance has caused additional current flow.

Dave
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Old 07-11-2013, 08:20 AM   #8
TxPowderCoater
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Default Re: 48V charger keeps tripping 15A breaker

Quote:
Originally Posted by speedgolfer View Post
Charger draw between 9 and 10 amps and then stretching it out another 25 ft makes it draw 11 or 12 and a 15 amp breaker you are only suppose to load it 80 percent so check the size of wire (it will say on it) 14/2 or 12/2 if its is 14/2 it is 15 amp or 12/2 then put 20 amp breaker
Quote:
Originally Posted by Dave Box View Post
If you lengthened the low voltage cables and now have a problem it would seem logical to reinstall the original cables to see if the problem is resolved. As a spec guess I would say that additional resistance has caused additional current flow.

Dave
He said he didnt lengthen, he just planned on making the change to heavier wire, if you read up, he said he put it back together after checking low voltage wire hole diameter and now has a problem after basically changing nothing.
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Old 07-11-2013, 08:46 AM   #9
Dave Box
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Default Re: 48V charger keeps tripping 15A breaker

Yes indeed mea culpa, apologies.

Dave
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Old 07-11-2013, 11:42 AM   #10
cgtech
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Default Re: 48V charger keeps tripping 15A breaker

so, let me get this straight.... everything has been returned to original configuration, and it still doesnt work?
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