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Unread 10-05-2016, 11:19 PM   #31
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Default Re: Lester on board charger review

I got a 48v LED Thank you

Should I use a 3a or a 1a diode ?

I am waiting for some new thermal compound to mount the charger on an ezgo rib vented heat sink too.
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Unread 10-06-2016, 10:12 AM   #32
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Default Re: Lester on board charger review

I got this.
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Unread 10-06-2016, 09:46 PM   #33
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Default Re: Lester on board charger review

Thanks to Sergio I got it.
There was some trial and errors and some head scratching... when I quit I had an arm load of tools and gadgets pulled out. Laptop on a stool next to the cart to monitor safety interlock and accelerator activity.
I screwed the controller up so hard I had to revert to default settings once. But I got it now:
The cart runs normal without the charger plugged in (wasn't the case when I started) lol
When the charger is plugged in the key switch feed to the control is cut off disabling the solenoid activation circuit... that's a definite no go situation.
When the charger is plugged in and the key is turned on a RED LED lights up next to the key and the cart will not run.
Unplug the charger and the RED LED goes out and the cart runs.
Here is all that really is needed.

Find the yellow wire at pin 9 in the big main Molex connector that plugs into the controller. Remove this wire from the plastic sheath and cut it where you can easily install 2 but connectors. I found this spot about 4 inches away from the Molex connector. I extended each end of the cut yellow wire 12 inches and put a smallish 0.250 spade connector on each one.

The LESTER interlock wire has a lot of plastic shield on the spade connector but once I snipped and tore the shield away I was able to pinch the connector so it would fit the relay terminal snug. The other half of the trigger circuit was a simple 48v (+) constant supply. You can get this from a few places like; battery main (+), solenoid large terminal, Run/Tow switch feed.

At this point the relay works and disables the cart IF the original charge outlet is left intact...but I want to remove it and install my AC plug house in it's place. This will require a new 48(+) constant feed to the orange wire with red strip... remember this wire? Pin 5 in the Alltrax XCT must have 48v(+) for the controller interlock to be off.

I have some more work to do to wrap everything up - I want to add an intermittent beeper to the warning system. And tidy everything up.
Here are a few pics.
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File Type: jpg interlock indicator.jpg (129.9 KB, 0 views)
File Type: jpg interlock armed.jpg (177.2 KB, 0 views)
File Type: png 10-05-16.png (26.0 KB, 0 views)
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Unread 10-06-2016, 11:28 PM   #34
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Default Re: Lester on board charger review

Don't You think it would be better to power the positive side of the Relay coil from Key Switch power as well (same as Relay COM terminal)?

The way You have it now, the relay will be powered the entire time the charger is plugged to the AC outlet, not just when it is actively charging.

If the "Charger Interlock" input on the XCT controller is just another interlock and it is irrelevant when key switch is OFF (no walkway brake function with key OFF), You can plug the Controller Pin#5 to the negative side of the relay coil where the Lester Interlock is plugged.

That way when the charger is unplug from the AC outlet and the key switch is ON, the relay coil will act as a "pull-up" resistor and provide the +48v logic power needed to disable the XCT Interlock.
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Unread 10-07-2016, 12:56 AM   #35
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Default Re: Lester on board charger review

I guess I misunderstood - I will change the (+) side of the trigger to join the Common.
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Unread 10-07-2016, 01:49 PM   #36
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Default Re: Lester on board charger review

okay now we got it going on. Sergio might even approve. I have shared the common (yellow ignition wire) with the relay switch circuit so the relay is only on when the key is switched on - as previously discussed. Sorry I missed that but, thanks for correcting me. This is the way we want the relay to activate.

PS
I added a beeper to the warning system. I used a standard intermittent 48v GC beeper, stuffed a bit of foam in the speaker hole to tone it down a bit. Could have also put the ground on a lower voltage (-) source but for now it was easier to tap the battery meter lead, see pics. Everything working as intended and I'm convinced it is as safe as the OEM. We have noise and lights. Only thing we don't have is a loudspeaker " step away from the vehicle, put your hands in the air"

Thanks for your patience Sergio. I enjoyed the challenge & I could not have tackled it without your help

PS
The last picture shows the Alltrax pin 5 lead connected to battery (+) so that the control will not enter a safety lockout when I disconnect the OEM charge port in preparation for the AC cord housing receptacle to come.... I connected this into the Run/Tow supply line as shown.

More to come:
Remount charger on Ezgo heat sink
Swap charge port with AC cord housing from Pro Mariner
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File Type: jpg complete.jpg (38.5 KB, 0 views)
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Unread 10-08-2016, 07:49 AM   #37
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Default Re: Lester on board charger review

As mentioned Pro Mariner makes a direct replacement AC cord receptacle for Ezgo TXT. (But they make a not so good on board charger)
This is not a plug. It is just a cord end housing, see pics

Easy enough to drill out the 4 aluminum pop rivets and install with 4 standard molly type rivets using my HF pneumatic riveter. Result is a clean easy AC access.
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Unread 10-08-2016, 07:52 AM   #38
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Default Re: Lester on board charger review

Mounting the charger to an OEM controller heat sink was a good idea but the charger stood up too tall for the seat to clear & the heatsink design did not lend itself to modification, so this idea was abandoned.
I will get some charge results now that the install is complete. Currently the dog and I are running the batteries down some

Here is the relay drawing as installed. Remember pin 5 needs 48(+) to keep lockout deactivated.
If you remove the OEM receptacle as I did, you will need to reconnect pin 5 to 48v(+).

Again thank you Sergio for your help
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Unread 10-08-2016, 02:37 PM   #39
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Default Re: Lester on board charger review

I installed an analog amp meter so I could see what phase the charger was in based on the voltmeter reading and the amount of amperage flowing.

The charger gave a long 5a leveling phase and cut off at 64v or 2.67vpc then went to a float level of 52v or 2.17

I installed the DC reducer, fuse panel, and ground block while I waited.
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Unread 10-08-2016, 09:19 PM   #40
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Default Re: Lester on board charger review

Working on the cart is fun but Hash Tag needed a break so we put the tools away and drove out the back gate for a ways till it got too rough for the street cart.
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