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Electric Club Car Electric DS, and Precedent golf cars |
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03-08-2014, 08:26 AM | #1 |
Not Yet Wild
Join Date: Mar 2013
Location: Ave Maria/Naples, FL
Posts: 35
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Convert external charger to on-board
I have a pretty beaten up PowerDrive charge that came with an equally rough looking 2002 IQ. I have had an issue of when the wife takes the cart and puts it back she doesn't always seat the charge plug all of the way in and it does not charge. This was discovered the hard way. I recently had the flip bed and body of for some paint and I figured I would add the charger in the bagwell while all the rusted hardware was removed and stainless was going back on. I routed the wires and relocated the cart's receptacle in the battery area and I didn't even think of a safety lock that wouldn't allow the cart to drive while connected to the charger.
Long story short, I now have to plug in my 110v plug and flip the seat up and plug and unplug that firm/stiff 48v plug that I was hoping to never have to deal with again. I know the 3 wires of my 48v plug are +, -, and communication for OBC, but is it some sort of redundant signal or can I cut the wire on the receptacle side and add a switch or relay to open or close that circuit when the key is on/off? I know how to wire relays but I don't know much about these chargers. I searched onboard chargers and that just netted the real OEM ones. I looked but didn't seem anything else exactly as I was trying to do...Advice? Once this is figured out I plan to add a 25-50' retractable extension cord inside the vehicle as I have plans to make it a little cooler looking and more simple/functional. I now have a spot at work I can plug in so the clean cord would be a plus. |
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03-08-2014, 08:52 AM | #2 |
Medicare Recipient
Join Date: Jun 2011
Location: West Michigan
Posts: 3,541
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Re: Convert external charger to on-board
. . . removed . . .
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03-08-2014, 09:02 AM | #3 | |
Not Yet Wild
Join Date: Mar 2013
Location: Ave Maria/Naples, FL
Posts: 35
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Re: Convert external charger to on-board
Quote:
The plus is in the battery area now, along with the receptacle that I removed from the body and it all now lays between the batteries. I guess I'm not seeing what is different in this situation. |
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03-08-2014, 09:08 AM | #4 | |
Medicare Recipient
Join Date: Jun 2011
Location: West Michigan
Posts: 3,541
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Re: Convert external charger to on-board
Quote:
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03-08-2014, 09:31 AM | #5 |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,419
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Re: Convert external charger to on-board
An other thing to consider is that the standalone charger may not hold up well to the vibration, heat, and dirt exposure associated with on-board installation.
Might be better to teach the better half 1. how to seat the plug 2. wait to hear the charger come on or see the needle move |
03-08-2014, 09:39 AM | #6 | |
Not Yet Wild
Join Date: Mar 2013
Location: Ave Maria/Naples, FL
Posts: 35
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Re: Convert external charger to on-board
Quote:
So Scotty, how can I better shield this charger from the elements? I like the idea of being able to charge places other than home as well as not have the charger in the way on the garage floor Can the terminals be "lubed" up with an electrical friendly grease like dielectric grease and ease the insertion of the plug? I took the plug apart and the barrels of each wire receptacle have a wire that holds the tip together, this is good for a positive connection that doesn't fall out but that makes for the stiffer push. |
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03-08-2014, 09:45 AM | #7 | |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,419
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Re: Convert external charger to on-board
Quote:
Some synthetic grease will lube the connection but it will also attract and old dirt and debris which ultimately will hinder the contact or insertion of the plug. |
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03-08-2014, 09:49 AM | #8 |
Medicare Recipient
Join Date: Jun 2011
Location: West Michigan
Posts: 3,541
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Re: Convert external charger to on-board
. . . about once or twice a season I spray WD40 into the receptacle on the cart . . . plug goes in and out like crap through a goose . . .
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03-08-2014, 10:44 PM | #9 |
revolutiongolfcars.com
Join Date: Mar 2010
Location: Golf Car Capital of The World... Augusta, Georgia
Posts: 10,224
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Re: Convert external charger to on-board
Either spray some WD40 in the charger receptacle to make it work smoothly or put a toggle switch on the sense lead. These carts are designed not to run when the DC cord is plugged into the vehicle whether the AC cord is plugged in or not. Club Car On-Board chargers have an AC interrupt circuit board installed in them that will allow the cars to run with the DC Cord inserted. These boards are rather pricy. Simple solution would be the toggle switch.
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03-09-2014, 08:17 PM | #10 | |
Not Yet Wild
Join Date: Mar 2013
Location: Ave Maria/Naples, FL
Posts: 35
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Re: Convert external charger to on-board
Quote:
You can see below that the sense lead seems to just piggyback off of the ground. Maybe I don't fully understand how this circuit works but I would think it would be a varried current or maybe signal (pulsed). Is it really that simple? PS, the wd40 trick made it way better (used bike chain lube as it's all I could find). Edit: Just kidding. The sense is the thinner, fused wire in the yellow holder right? Last edited by yetti96; 03-09-2014 at 08:22 PM.. Reason: Looked again |
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