PDS acrs when connecting battery terminal

[rockfordpi]

Yes, I understand spark behavior on solenoid wire now, however the spark on white charge wire never stops

Sent from my HTC One M9 using Tapatalk

[Sergio]

Since the Controller capacitors should charge via the pre-charge resistor, maybe you have other issues.

Does it still spark when the cart is in neutral?

Not much of a wiring diagram I can find, more like harness routing, so maybe folks here with more understanding of that system call tell you how the power flows from the reed switch so you can open each of the interlocks in the right sequence to test.

[rockfordpi]

Originally Posted by Sergio

Since the Controller capacitors should charge via the pre-charge resistor, maybe you have other issues.

Does it still spark when the cart is in neutral?

Not much of a wiring diagram I can find, more like harness routing, so maybe folks here with more understanding of that system call tell you how the power flows from the reed switch so you can open each of the interlocks in the right sequence to test.

I have not checked in neutral.

looking at the PDS diagram in the sticky above, as best as I can trace it, it appears the only thing that could cause the charger wire to arc is the red/white wire from the reed switch.

There is no short between the +/- pins in charger port and I still get the arc with the main power wire going to solenoid removed. So, the only place it could find a circuit would be through the reed switch via pin 4 of J1 connector. After it gets to J1, I lose the wiring diagram and logic, somewhere pin 4 has to be connecting back to negative.

[Sergio]

I found the old Altrax DCX wiring diagram for PDS has enough info to at least give you the current path from the reed switch:

Pack Positive -> charger receptacle reed switch - hot side

Charger Receptacle reed switch on/off -> J1-4

J1-4 -> J3-3 (Tow/Run switch hot side - Red/White wire)

Tow/Run switch on/off (Orange/Red wire) -> J3-4 (Controller Logic Power)

J3-4 -> J1-1 (Orange/Red wire to Blue wires on FNR)

FNR Forward (Green wire) -> J1-3

J1-3 -> J1-9 (Key Switch hot side - White wire)

Key Switch on/off (Yellow/White wire) -> J1-8 (Key switch power)

J1-8 -> J1-7 (Solenoid positive wire Yellow)

J1-8 -> J4-2 (ITS foot switch hot side - red wire)

ITS foot switch on/off - Green wire -> J4-1 (Controller foot switch)

Some of those connector pins are internally connected to pins in other connectors.

So the sequence of interlocks in series are: Tow/Run switch -> FNR Switch -> Key Switch -> ITS micro-switch.

[Sergio]

You should always have your cart in "Tow" when connecting or disconnecting the battery cables.

If the cart is on "Run", the current You are seeing maybe the quiescent (idle state) current needed for the Controller to power the speed sensor and monitor the inputs.

You can always put your multi-meter set to DC current in series with that white wire to measure exactly how much current is being drawn.

The interesting thing to point it out, if the "spark" is caused by the normal quiescent current, that "spark" will occur inside the reed switch every time You plug/unplug your charger plug.

[rockfordpi]

Originally Posted by Sergio

I found the old Altrax DCX wiring diagram for PDS has enough info to at least give you the current path from the reed switch:

Pack Positive -> charger receptacle reed switch - hot side

Charger Receptacle reed switch on/off -> J1-4

J1-4 -> J3-3 (Tow/Run switch hot side - Red/White wire)

Tow/Run switch on/off (Orange/Red wire) -> J3-4 (Controller Logic Power)

J3-4 -> J1-1 (Orange/Red wire to Blue wires on FNR)

FNR Forward (Green wire) -> J1-3

J1-3 -> J1-9 (Key Switch hot side - White wire)

Key Switch on/off (Yellow/White wire) -> J1-8 (Key switch power)

J1-8 -> J1-7 (Solenoid positive wire Yellow)

J1-8 -> J4-2 (ITS foot switch hot side - red wire)

ITS foot switch on/off - Green wire -> J4-1 (Controller foot switch)

Some of those connector pins are internally connected to pins in other connectors.

So the sequence of interlocks in series are: Tow/Run switch -> FNR Switch -> Key Switch -> ITS micro-switch.

THANK YOU SO MUCH!

I am assuming the reed switch is normally closed and the charger plug opens it?

[Sergio]

Correct, the little magnet in the charger plug "opens" the reed switch when inserted into the cart receptacle.

I understand they are a typical area of problem on EzGos since reed switches are not designed to handle much DC current during make/break.

[scottyb]

Ezgo did away with the reed switch in 05 when the controller safety interlock was introduced