DPI charger for 48 volt

[Goober11]

Originally Posted by Fairtax4me

More than likely it has either a poor connection at one of the wire terminals or a bad relay.

The rectifier may not be good, but you should still hear a click and the transformer should start humming when the charger is plugged into the cart.

With it UNplugged from the wall AC power, Plug the DC cord into the Cart.
Listen and feel for the relay to click. If it does not Check for pack voltage reaching the relay.
One of the two wires on the top of the relay is pack voltage and it should have that black wire from the transformer spliced to it.
The other wire should have continuity to Pack Negative if the OBC is telling the relay to turn on.
Check for poor connections or corrosion at the terminals at the relay.
Check for bad connections in those wire nuts also. Those really should be crimped on terminals, but it looks like someone replaced the charge cord at some point and just used what they had laying around to connect the wires.

If you have pack voltage on one pin, and continuity to pack negative on the other pin at the relay. The relay is bad.

The next step would be to either bypass the AC side of the relay, or remove the relay and test it individually.

To bypass the AC side you can either make a jumper with spade terminals, Or connect the transformer supply wire straight to the circuit breaker. Remove the short wire that runs from the breaker to the relay, and remove the large black wire that goes to the transformer from the relay and plug it to the breaker. Now if you plug in the AC cord you should hear the transformer hum, even if the charger is not plugged into the cart.

Unplug it from AC power, plug the charge cord into the cart, and then plug back into AC power and the transformer should come on immediately and the ammeter should jump up and show that it is charging.

Bypassed AC side like you suggested. Transform did hum. Unplug AC power,plunged the Charger cord into cart,then plugged back to AC power. Transformer did hum for a few seconds but then kicked 15 amp breaker on charger. Amp gauge didn’t move.


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[mgray70]

Originally Posted by Goober11

Bypassed AC side like you suggested. Transform did hum. Unplug AC power,plunged the Charger cord into cart,then plugged back to AC power. Transformer did hum for a few seconds but then kicked 15 amp breaker on charger. Amp gauge didn’t move.


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That could be that bridge rectifier bad. At $3.55, I would give it a try.

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[Goober11]

Ok thanks I will order one.


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[Sergio]

Your picture on the first post shows the bridge rectifier is unplugged, make sure it is plugged correctly, transformer wires go to the "~" terminals.

[Goober11]

Originally Posted by Sergio

Your picture on the first post shows the bridge rectifier is unplugged, make sure it is plugged correctly, transformer wires go to the "~" terminals.

Thanks Sergio I will check that. The first pictures was how it was when I got it.


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[Goober11]

Not sure but it looks like it is wired wrong.


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[Goober11]

Originally Posted by Goober11

Not sure but it looks like it is wired wrong.


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Looks like I need to switch amp gauge an the other transformer wire.


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[Sergio]

What You are still missing is a piece of wire between the "+" on the bridge rectifier and the two white wires with the wire nut (positive wire to DC cord).

[Goober11]

Originally Posted by Sergio

What You are still missing is a piece of wire between the "+" on the bridge rectifier and the two white wires with the wire nut (positive wire to DC cord).

Added wire from + terminal on bridge rectifier to the two white with the wire nut. Plugged up to cart an wall receptacle still nothing.

I have a bridge rectifier am relay on order. Should be here tomorrow.


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[Sergio]

You definitely needed that wire for the charger to work.

Make sure You also test the diode on the relay since a bad diode will damage the OBC.