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Old 10-06-2019, 12:13 AM   #1
RaptorDave
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Join Date: Oct 2019
Location: SoCal
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Default Total Charge III Not Charging

The charger was weathered and the relay on the control boards solder joints became loose. I replaced the board with the new updated one and the charge is still not putting out.

Melex Cart Model 112
* Someone removed all batteries and cables and I used the attached diagram to wire the cart identically. Cart drives fine.
* I removed all the cables and charged each 6v battery individually, total 36v
* When the charger is plugged into the cart, I can hear it click and start humming, very slightly.
* The Meter on the front of the charger does not register, it did prior to the cold solder joint problem on the control board
* I replaced the (MOV2 varisitor) a year ago from being burnt

* How can I test the charger to verify if or what if any current it's putting out?
* What other parts may be bad the could be tested?

Any thoughts?

Dave
Attached Images
File Type: jpg Control Board Potter & Brumfield SDA-2056 copy.jpg (187.2 KB, 0 views)
File Type: jpg Amazon $43.95.jpg (36.7 KB, 0 views)
File Type: jpg Charger Diagram-1.jpg (17.6 KB, 0 views)
File Type: jpg New Board Installed copy.jpg (175.4 KB, 0 views)
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Old 10-06-2019, 12:16 PM   #2
JohnnieB
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Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
Default Re: Total Charge III Not Charging

The control board is a semi-smart switch that only controls switching the AC power to the transformer on and off. It has no other influence on the charging process.

The actual battery charging circuit consists of the ferroresonant transformer, boost capacitor and diodes. An ammeter and circuit breaker are also in the charging circuit, but are ancillary items.

The transformer huming says the control board is working, it is humming softly and no deflection on ammeter says the charging circuit isn't putting out many amps. Could be a blown diode or both, or could be a bad capacitor.

Attached is how to test the transformer and capacitor.
Also a service and parts manual for the TC-III is attached.
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File Type: jpg Transformer-Capacitor test.JPG (66.2 KB, 0 views)
File Type: jpg Transformer-Capacitor test - Text-1.jpg (367.7 KB, 0 views)
Attached Files
File Type: pdf Total Charge III Parts and service-1.pdf (3.28 MB, 0 views)
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Old 10-06-2019, 03:00 PM   #3
RaptorDave
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Default Re: Total Charge III Not Charging

You fine Sir, are Da Man!
Thank You for your quick response, it's what I hoped for but wasn't what I expected, it way exceeded that.
I will test the thing out and hope to have a positive reply with a huge smile.
If I can't find the problem with the info you provided, I shouldn't be touching it anyways 😆😂

Have a Beautiful Sunday

D
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