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Old 11-10-2016, 11:40 AM   #21
JohnnieB
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Default Re: charger not cutting off

Quote:
Originally Posted by gbeach View Post
I took both of those readings with the charger unplugged
38.3,38.2 before charging
43.5,42.5 after charging
the 47 was while charging
so you think that 1 volt drop is normal
No. There shouldn't be any voltage drop, or at least not more than a few millivolts.

There is about 6' of 8Ga wires between the charger port and batteries and with 10A of charging current passing through them, the nominal voltage drop of the copper conductors is 0.038V. You can add a few more Milli-ohms of unavoidable resistance in the connections, but with 10A of current flow you should see less than 0.1V difference and without the charger connected, there shouldn't be a measurable difference (unless you are using a DVM that resolves down to micro-volts)
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Old 11-10-2016, 11:46 AM   #22
gbeach
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Default Re: charger not cutting off

okay. gonna try new cables first. what else is there to try.
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Old 11-10-2016, 01:38 PM   #23
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Default Re: charger not cutting off

If you can measure 47V at the main battery terminals while the charger is pumping amps into the battery pack and the charger is shutting off normally when attached to a different cart, the problem is somewhere between the main battery terminals and the charger port.

Personally, I'd cut off about an inch or so of the existing 8Ga cables at the battery end and install new 5/16" ring terminals (solder on type preferred), then reconnect the new ring terminals directly to the battery terminals, leaving out the fuse if one is installed.

If you have kids or anyone that might place a metal object in the charge port and short between the +/- radsoks, put the fuse back in the circuit after the charger is working correctly.

---------
The trick is to get the same voltage at both the main battery terminals and the charger port.
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Old 11-10-2016, 01:59 PM   #24
gbeach
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Default Re: charger not cutting off

yeh you know I though about trying that first. don't know if I have enough cable length. yes I am definitely soldering them. I'll let you know how it goes.
thanks for the ring terminal size, I didn't have that size at my work.
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Old 11-10-2016, 02:00 PM   #25
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Default Re: charger not cutting off

didn't see a fuse
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Old 11-10-2016, 02:27 PM   #26
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Default Re: charger not cutting off

Not all carts have them.

There was one on my cart when I got it (lower right in attached picture), but I have since removed it.
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Old 11-10-2016, 02:30 PM   #27
gbeach
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Default Re: charger not cutting off

thanks for all your help. gonna try the ring terminals tonight
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Old 11-10-2016, 03:35 PM   #28
gbeach
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Default Re: charger not cutting off

man if that doesn't help where do I go next.
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Old 11-11-2016, 08:01 AM   #29
gbeach
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Default Re: charger not cutting off

put on new ring terminals at battery connection and soldered. fixed it, charger shut off after hour and a half. still thinking about running new wires, but it looks like 10 gauge after going to home depot. cant really tell.
thanks for your help.
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Old 11-11-2016, 09:03 AM   #30
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Default Re: charger not cutting off

The original wires might very well be 10Ga, but if possible and practical, use 8Ga.
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