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Unread 09-28-2016, 10:23 AM   #11
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Default Re: Lester on board charger review

Scottyb, I just did a quick look at the Lester manual and the charger definitely needs to be set for Lockout Option 1.

The option 2 only floats (no pull up power) when charger is not active.
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Unread 09-28-2016, 11:06 AM   #12
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Default Re: Lester on board charger review

Sergio - Thanks for your input. Judging from what I have read this is a factory setting option. Do you agree?

I'm going to verify the voltage up/down readings today to see what we are working with.

Here is what I am working with.
Lester 2800 48v. The pack voltage is 50.5v at rest
The safety interlock wire wire aka the blue wire readings without AC plugged into the unit are 34.6v at the blue wire without it being connected to anything and the charger off (no AC plugged in)
The blue wire reading drops to 26.6v when connected to the orange wire w/red strip aka XCT pin 5

With the charger plugged into the AC I read 0.7 on the blue wire without it connected to anything and 0.5 with it connected to XCT pin 5

With the XCT program open I select show charger interlock and select the High/Low option
The cart runs with and without the charger plugged into the AC and pin 5 is seeing 26.6/0.5 volts

I am waiting for Alltrax to call

Meanwhile I tested the OEM system voltage at pin 5 and here are the results ( this system works as intended)
Without charger plugged in 34.3 volts = cart runs
With charger plugged in 4.25 volts = cart does not run
Simply disconnecting pin 5 input results in 4.25 reading and cart does not run.

I think we found the discrepancy.
Cart lock out signal 4.25v
Lester lock out signal 0.5v
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Unread 09-28-2016, 01:02 PM   #13
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Default Re: Lester on board charger review

Yes, it looks like a factory set.

I think Your readings are being affected by your meter.

They use a "pull-up" resistor to keep the voltage high (near battery voltage) on the lockout circuit, which is intended for use with high-impedance controller inputs.

If You are using a fluke with a low-impedance setting (like the Auto-Z function), it will probably cause a voltage drop on the pull up resistor and get you a lower reading.

Set your fluke to the regular DC volts setting as it should be high impedance, the voltage on the Lester "blue" wire without the charger plugged to AC (but plugged to the batteries), should be closer to battery voltage.

Sorry for the obvious question, but you don't have the interlock connected to both onboard Lester and OEM system at the same time, right?
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Unread 09-28-2016, 02:21 PM   #14
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Default Re: Lester on board charger review

Quote:
Originally Posted by Sergio View Post
Yes, it looks like a factory set.

I think Your readings are being affected by your meter.

They use a "pull-up" resistor to keep the voltage high (near battery voltage) on the lockout circuit, which is intended for use with high-impedance controller inputs.

If You are using a fluke with a low-impedance setting (like the Auto-Z function), it will probably cause a voltage drop on the pull up resistor and get you a lower reading.

Set your fluke to the regular DC volts setting as it should be high impedance, the voltage on the Lester "blue" wire without the charger plugged to AC (but plugged to the batteries), should be closer to battery voltage.

Sorry for the obvious question, but you don't have the interlock connected to both onboard Lester and OEM system at the same time, right?
I will retest with meter reset as suggested.
I have cut the wire the pin 5 and spliced it back together using spade connectors so I can plug either the OEM or the Lester safety disconnect lead in but not both. All pin 5 readings were taken at this junction.

Alltrax tech and I went over this some. They thought maybe it was the controller safety function selection. Choices are high/low and floating/NC
(I assume NC = no current) So any current/no current.


At this time

When high/low is selected the cart will not run with or without the lester charger plugged in. The monitor shows charger plugged in all the time

When float/nc is selected the cart will run with or without the lester charger plugged in. The monitor fails to recognize when the Lester charger is plugged in HOWEVER it does recognize the OEM charger plugged in in both modes.

Alltrax and I are stumped


Both the Lester and the OEM send 0.5v to pin 5
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Unread 09-30-2016, 03:11 PM   #15
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Default Re: Lester on board charger review

After 2 days I finally got together with a Lester tech support guy who was nice enough to explain a few things.
#1 being something I missed = the interlock wire actually pulls to negative voltage when AC is applied to the charger. My meter was not reading this polarity change.
So - that's why it was not working with the Ezgo or Alltrax lockout system.

Here is their tech note and fix... this looks quite doable... I'll have to look in my charger parts box to see if I have a suitable relay.
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File Type: jpg lockout.JPG (71.5 KB, 0 views)
File Type: jpg unnamed.jpg (23.7 KB, 0 views)
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Unread 09-30-2016, 07:30 PM   #16
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Default Re: Lester on board charger review

I tried to find the part # given for 48v
So I correct me somebody but can I not use any 48v 10a DPDT relay?
All we need to do is make and break a circuit.
How about > http://www.ebay.com/itm/Potter-Brumf...-/261706094126
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Unread 09-30-2016, 09:21 PM   #17
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Default Re: Lester on board charger review

So it looks like the charger is factory set for Option #2 (Float mode - no pull up resistor when the AC is unplugged).

The cart you are testing must have that fancy circuit board on the OEM charger receptacle that provides both +48v and 0v for interlock (instead of a simple on/off reed switch).

I don't really like the proposed implementation since it would keep the relay powered the entire time the charger is plugged in, even in storage for an extended period of time.

I would get the +48v power for the relay coil from the key switch as well, so the Relay would only energize (and break the circuit), if the key switch was turned ON with the charger plugged to AC.

The relay contacts would open in less than 0.015sec after the key switch was turned ON, so no chance of anything happening.

You can even run a wire from the N.O. contacts to the reverse buzzer, so if the key switch was turned ON while the charger was plugged, the power would go from key switch to reverse buzzer.

Here is a link for the +48v SPDT relay:
http://www.mouser.com/Search/Product...55-T9AP5D52-48
I think Lester interlock option #1 would work best for most controllers, specially the Curtis in Club Cars.

I am not sure about Alltrax, but there is a big difference in the Curtis handling of the charger interlock vs. just interrupting the key switch power.

When the charger interlock is enabled, most of the controller logic is put to sleep, no power to speed sensor, no checking for "walk-away" condition, no power on the Field drivers, no reverse buzzer, etc...

Another way of handling their Option #2, I think mentioned in the Lester specs, is to use a 10kΩ - 1watt resistor connected to the Blue wire and to a +48v power source after the Tow/Run switch.

That would provide both active +48v (with the pull-up resistor) and 0v (Lester default behavior).

It would also consume about 1/4 of the relay coil power when active and practically no current when the charger was unplugged as the logic input of the controller requires only micro-amps to detect the "High" state.
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Unread 09-30-2016, 09:33 PM   #18
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Default Re: Lester on board charger review

Thanks Sergio - Is this the right type resistor? https://www.amazon.com/RESISTOR-META.../dp/B008UTWNX0
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Unread 09-30-2016, 10:02 PM   #19
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Default Re: Lester on board charger review

I meant to type 1 watt not 2 watts as the maximum power will be about 0.25 watts (I edited the post).

Quite a markup on amazon, the resistor is only 10 cents.
http://www.mouser.com/ProductDetail/...zOC9bCL9VxU%3d
Edit: If a relay is used it needs a diode on the relay coil.
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Unread 10-01-2016, 12:32 AM   #20
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Default Re: Lester on board charger review

Quote:
Originally Posted by Sergio View Post
I meant to type 1 watt not 2 watts as the maximum power will be about 0.25 watts (I edited the post).

Quite a markup on amazon, the resistor is only 10 cents.
http://www.mouser.com/ProductDetail/...zOC9bCL9VxU%3d
Edit: If a relay is used it needs a diode on the relay coil.

I want to try the resistor thing. I'm not clear on where it goes.
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