powerwise charging issues

[dannyvp]

ok heres what i know as of now..........
The "loose" black wire, is attached to a red wire coming from the charging plug.
I also attached the loose red wire to one of the plugs on the alum plate. There was two, i just picked the top one.After i check some voltage in a few days i will post something.

[JohnnieB]

Originally Posted by dannyvp

ok heres what i know as of now..........
The "loose" black wire, is attached to a red wire coming from the charging plug.
I also attached the loose red wire to one of the plugs on the alum plate. There was two, i just picked the top one.After i check some voltage in a few days i will post something.

Yes, that is were it goes, but did you connect the loose end to the control board?
It might not be loose, but that is how it looks to me in the first picture.

If it was loose, every thing is connected as it should be.

[dannyvp]

those 2 wires, the red and black are soldered on. so i should be good to go there.

[JohnnieB]

[dannyvp]

Ok when i showed up and checked the batteries they read, 28.14.
The cart would not charge, so i jumped the relay and let it charge for around 10 hours.
Then the batteries read 36.61.
I un jumped the relay and it still will not charge.
After re reading your post above, i may not have allowed them to charge enough to be at full charge, but it should have turned on the charger after unjumping it.

Will the relay not allow charging if the black wire for the Aux contact is messing up?

[JohnnieB]

Originally Posted by dannyvp

Ok when i showed up and checked the batteries they read, 28.14.
The cart would not charge, so i jumped the relay and let it charge for around 10 hours.
Then the batteries read 36.61.
I un jumped the relay and it still will not charge.
After re reading your post above, i may not have allowed them to charge enough to be at full charge, but it should have turned on the charger after unjumping it.

Will the relay not allow charging if the black wire for the Aux contact is messing up?

Yes. The Aux contact is where the control board gets the voltage to close the relay and turn on charger.

[dannyvp]

Here's a pic of my charging handle. Looks like its fine to me. I was hoping that center piece was not in place, then it might have been an easy fix. What do you think.

[JohnnieB]

They are dirty/corroded, and need a good cleaning or replacement.

The brass the Male Radsoks are made from, should look as good as their female counterparts in the photo attached to post#3 in this thread.
The Aux. contact (In the middle) is tinned Beryllium-Copper and should be silver-like in color. (Similar to soldered copper plumbing joint or copper wires soldered together.)
Also the push-on connector between red wire and Aux, contact looks corroded.

I suspect the Female Radsoks in the cart's charging receptacle need some TLC also.
The Aux. Contact touches the outside of the negative Female Radsok, that is where the charger senses the pack voltage.

[dannyvp]

Johnnie im thinking they need replaced! I may clean them just to see if i can get the charger to work and then replace them once i know they are the problem. As of now i still dont know if the board is bad or if its these little corroded pieces.

[JohnnieB]

The smaller red and black wires that attach to the control board in the upper left corner of the picture you posted are the battery sense wires.
The red one attaches to the heat sink and the black one attaches to the output cable and then on to the Aux. contact in the charger plug.

Plug charger into cart, but DO NOT plug the charger into AC power.
Measure the voltage between the red and black wires.
It should be EXACTLY the same as the voltage measured at the main + & - battery pack terminals.
If it isn't, there is undesired resistance in the wires or connections.

If it is the same and about 30V or more, the relay should click. (The charger does not have to be plugged into AC power for relay to click!!!)
If it doesn't, the control board is bad.