Troubleshooting not charging

kpauley · 12-19-2017, 03:57 PM

I don’t work on these carts for a while and I forget things!

99 EZGO upgraded to 42 volts. SPM controller, Trojan batteries and a DPI charger. Things have been running well for quite some time, then a couple months ago I noticed it was not charging. Ended up having some errors on the charger and had to swap out the board.

Things worked fine since. Now I have a cart not charging again. This time no errors on the charger. The Power On and Detection lights are red. Doesn’t sound like it is clicking and trying to sense the pack.

Nothing else has changed, I’m manually charging up the pack so I can continue to use the cart and I’m getting the voltage up past where it should sense the pack.

Have not measured individual cells yet but will do so, just seems like something is not triggering the charger and I want to make sure I am looking for the right things :-).

atr42flyer · 12-19-2017, 05:46 PM

its the fuse blown?

kpauley · 12-19-2017, 06:01 PM

I checked fuses. They look fine. I’m seeing pack voltage at the receptical for the charger.

cgtech · 12-20-2017, 12:03 AM

Charger shows lights, but no change if Ac cord is plugged in or not? (And ac outlet works) If so, charger temp sensor may have failed.

kpauley · 12-20-2017, 02:45 PM

I'm working on a solid charge of all the individual batteries to make sure the pack is reasonably sound and will report back. May also try calling DPI tech support for the heck of it since I had a case with them before.

I did see some flickering of the lights on the charge when I plugged it in, went pretty quick, but it seemed to "know" that something changed but I didn't get any error condition lights after that.

kpauley · 12-21-2017, 01:41 PM

Got it figured out. Was getting pack voltage at the plug, but not at the charger itself. Opened up the plug on the charger cable and one of the screws that holds the terminal in place was loose and it looked like it had been arcing too as there was some plastic melted around it. Tightened that up and now it is charging. Gonna let it get through a whole charge, then I'll clean things up a little, make sure it is good and tight.

Golferdave · 12-21-2017, 02:07 PM

Quote:

Originally Posted by kpauley

Got it figured out. Was getting pack voltage at the plug, but not at the charger itself. Opened up the plug on the charger cable and one of the screws that holds the terminal in place was loose and it looked like it had been arcing too as there was some plastic melted around it. Tightened that up and now it is charging. Gonna let it get through a whole charge, then I'll clean things up a little, make sure it is good and tight.

Good find
Pics if you can ?

kpauley · 12-21-2017, 06:08 PM

Seems to be working better after I tightened up these screws. I’m assuming the melting of the plastic came from some arcing with the loose screw but if there is other stuff I should be concerned about let me know.

PingEye3 · 12-21-2017, 07:10 PM

Though you tightened the screw, that crimp connection that got hot while it was loose is no longer as strong as original and it will heat up. It is a weak link now. I think you should keep an eye on it especially about an hour into a charge, when the charger is still at peaks amps. Just a thought.

kpauley · 12-22-2017, 10:50 AM

I'm a little worried about it as well, was going to swap out the connector. But then DPI told me they would just send me a new cable and connector! Great customer service! Will be buying a DPI charger for my new (used) cart now!

12-19-2017, 03:57 PM	#1
kpauley Gone Wild Join Date: Dec 2010 Posts: 251	Troubleshooting not charging I don’t work on these carts for a while and I forget things! 99 EZGO upgraded to 42 volts. SPM controller, Trojan batteries and a DPI charger. Things have been running well for quite some time, then a couple months ago I noticed it was not charging. Ended up having some errors on the charger and had to swap out the board. Things worked fine since. Now I have a cart not charging again. This time no errors on the charger. The Power On and Detection lights are red. Doesn’t sound like it is clicking and trying to sense the pack. Nothing else has changed, I’m manually charging up the pack so I can continue to use the cart and I’m getting the voltage up past where it should sense the pack. Have not measured individual cells yet but will do so, just seems like something is not triggering the charger and I want to make sure I am looking for the right things :-).
kpauley Gone Wild Join Date: Dec 2010 Posts: 251

12-19-2017, 05:46 PM	#2
atr42flyer Not Yet Wild Join Date: Jul 2015 Location: Lakeland, TN Posts: 67	Re: Troubleshooting not charging its the fuse blown?

12-19-2017, 06:01 PM	#3
kpauley Gone Wild Join Date: Dec 2010 Posts: 251	Re: Troubleshooting not charging I checked fuses. They look fine. I’m seeing pack voltage at the receptical for the charger.
kpauley Gone Wild Join Date: Dec 2010 Posts: 251

12-20-2017, 12:03 AM	#4
cgtech Over This Interview Is... Join Date: Jun 2012 Location: AZ Posts: 17,449	Re: Troubleshooting not charging Charger shows lights, but no change if Ac cord is plugged in or not? (And ac outlet works) If so, charger temp sensor may have failed.

12-20-2017, 02:45 PM	#5
kpauley Gone Wild Join Date: Dec 2010 Posts: 251	Re: Troubleshooting not charging I'm working on a solid charge of all the individual batteries to make sure the pack is reasonably sound and will report back. May also try calling DPI tech support for the heck of it since I had a case with them before. I did see some flickering of the lights on the charge when I plugged it in, went pretty quick, but it seemed to "know" that something changed but I didn't get any error condition lights after that.
kpauley Gone Wild Join Date: Dec 2010 Posts: 251

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12-21-2017, 01:41 PM	#6
kpauley Gone Wild Join Date: Dec 2010 Posts: 251	Re: Troubleshooting not charging Got it figured out. Was getting pack voltage at the plug, but not at the charger itself. Opened up the plug on the charger cable and one of the screws that holds the terminal in place was loose and it looked like it had been arcing too as there was some plastic melted around it. Tightened that up and now it is charging. Gonna let it get through a whole charge, then I'll clean things up a little, make sure it is good and tight.
kpauley Gone Wild Join Date: Dec 2010 Posts: 251

12-21-2017, 07:10 PM	#9
PingEye3 Gone Wild Join Date: Sep 2014 Location: Orlando, FL Posts: 1,308	Re: Troubleshooting not charging Though you tightened the screw, that crimp connection that got hot while it was loose is no longer as strong as original and it will heat up. It is a weak link now. I think you should keep an eye on it especially about an hour into a charge, when the charger is still at peaks amps. Just a thought.

12-22-2017, 10:50 AM	#10
kpauley Gone Wild Join Date: Dec 2010 Posts: 251	Re: Troubleshooting not charging I'm a little worried about it as well, was going to swap out the connector. But then DPI told me they would just send me a new cable and connector! Great customer service! Will be buying a DPI charger for my new (used) cart now!
kpauley Gone Wild Join Date: Dec 2010 Posts: 251

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