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Old 10-25-2010, 12:11 PM   #1
CostaRica
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Location: Los Suenos Resort
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Default Hardwire the charger to the batteries

I would like to hardwire the DC cord from the charger into the batteries so that i only have to plug the AC cord in to the wall. Has anyone done this with success or has anyone tried it with problems? I would like in the end to have just one plug to worry about!!!

Any thoughts?
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Old 10-25-2010, 12:51 PM   #2
roady89
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Default Re: Hardwire the charger to the batteries

Yea...there is an issue doing that. When the batts get so low the relay in the charger comes on. IF you dont have it plugged in when the relay comes on it will drain your batteries.
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Old 10-25-2010, 01:14 PM   #3
CostaRica
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Default Re: Hardwire the charger to the batteries

Quote:
Originally Posted by roady89 View Post
Yea...there is an issue doing that. When the batts get so low the relay in the charger comes on. IF you dont have it plugged in when the relay comes on it will drain your batteries.
Thanks roady, is there a work around?
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Old 10-25-2010, 01:44 PM   #4
roady89
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Default Re: Hardwire the charger to the batteries

Not a SAFE work around. You would have to put a switch on the 120AC side of the relay. Not a very good idea. Not a real good way to do it.
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Old 10-25-2010, 07:27 PM   #5
rabbitreborn
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Default Re: Hardwire the charger to the batteries

buy a toggle switch rated at 30 amps. Wire the charger to the battery pack negative directly and to the positive side THROUGH the toggle switch. When running the cart, toggle switch in the "off" position, when you are ready to charge the cart, plug in the 120 AC, then flip the toggle switch to the "on" position.

I have personally wired about 50 carts in this manner and never had an issue yet.
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Old 10-26-2010, 05:57 AM   #6
aircat
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Default Re: Hardwire the charger to the batteries

Very sorry to take issue, but on the chargers I have worked with the relay contacts are on the primary side of the transformer, the 120v side, so relay on or off makes no difference. If the diodes are good in the charger the drain is nominal, about the same as a car alternator. However the switch on the battery side is still a very good idea.

Aircat
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Old 10-26-2010, 06:10 AM   #7
roady89
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Default Re: Hardwire the charger to the batteries

I can't count the times on here someone has left their chargers plugged in without the AC side plugged in and it drained their batteries. Not saying it wont work but if you let the cart set a few weeks or more (storage) your batteries will be dead. EZGO chargers use the battery pack to switch the relay. If I'm wrong, show me the diagram where the relay uses the AC side to switch. You can switch the DC charging side and it'll work as rabbit says
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Old 10-26-2010, 06:41 AM   #8
aircat
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Default Re: Hardwire the charger to the batteries

Ooooka You may have a good point there let me rethink my statement, I was thinking in terms of contacts not coil, but its the sensor circuit not the coil directly that's on the
DC side. Let me check the off state current on mine.

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Old 10-26-2010, 06:48 AM   #9
roady89
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Default Re: Hardwire the charger to the batteries

Yes, the batt voltage is sensed from DC side. If the voltage is too high (charged) it doesn't engage the relay. If the voltage is too low it wont engage the relay. Thats all handed on the PC board the relay is mounted on. The AC side of the relay is a make/break connection, it's not the relay pull in. I'm sure theres chargers that don't work this way but the ezgo Total Charge chargers do. My club car charger also uses battery to engage the relay.
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Old 10-26-2010, 07:23 AM   #10
aircat
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Default Re: Hardwire the charger to the batteries

Ok Roady You da man; even unplugged the relay coil gets energized "not what I expected" which brings the off state current to a whopping 57 milliamperes "also not what I expected". Soooo I need to retract my original statement entirely.

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