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Old 11-10-2016, 09:54 AM   #11
gbeach
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Default Re: charger not cutting off

I am open to any suggestions. I was going to run new wires from the charger input to the batteries. anybody know what gauge they are. look like 8 or 10.
I am wondering if I could still have a problem with charger even though it worked on my fatherinlaws cart.
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Old 11-10-2016, 10:08 AM   #12
gbeach
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Default Re: charger not cutting off

another question. what does the red wire actually do at the cart charger input.
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Old 11-10-2016, 10:19 AM   #13
JohnnieB
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Default Re: charger not cutting off

I did miss the post about it being at 47V.

The question now becomes, where was the 47V measured at?

The charger uses the voltage felt between the Red and Black wires attached to the control board to determine when to shut off. (See attached schematic with battery sensing circuit highlighted)

The Red wire (+) connects to the heat sink inside the charger.
The Black wire (-) connects to the outside of the negative radsok in the charge receptacle via the auxiliary contact in the charger plug.

The fact the charger works on a different cart indicates the problem in in your cart rather than in the charger, but does it still work on a different cart, or did it just used to work?
Attached Images
File Type: jpg PW Charger Schematic - Batt sense traced.JPG (47.8 KB, 0 views)
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Old 11-10-2016, 10:23 AM   #14
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Default Re: charger not cutting off

Quote:
Originally Posted by gbeach View Post
another question. what does the red wire actually do at the cart charger input.
If you are referring to the small red wire that comes out of the backside of the charge port, it disables the cart when the charger is plugged into the port, but doesn't have anything to do with the actual battery charging process.
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Old 11-10-2016, 10:24 AM   #15
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Default Re: charger not cutting off

Quote:
Originally Posted by gbeach View Post
I am open to any suggestions. I was going to run new wires from the charger input to the batteries. anybody know what gauge they are. look like 8 or 10.
I am wondering if I could still have a problem with charger even though it worked on my fatherinlaws cart.
Typically 8Ga.
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Old 11-10-2016, 10:25 AM   #16
gbeach
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Default Re: charger not cutting off

measured the 47 right at the batteries with the charger plugged in. dropped to 43.5 when I pulled the charger cord out. worked on my fatherinlaws cart. it shut off on his
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Old 11-10-2016, 10:27 AM   #17
gbeach
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Default Re: charger not cutting off

okay. well I guess I'll try new wires first from cart charger port to batteries.
don't think I should have a 1 volt drop on such a short run and large gauge wire.
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Old 11-10-2016, 10:28 AM   #18
gbeach
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Default Re: charger not cutting off

wonder why I didn't have a 1 volt drop before I charged. had 38.3 at batteries and 38.2 at cart input.
thanks for the input
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Old 11-10-2016, 10:56 AM   #19
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Default Re: charger not cutting off

Quote:
Originally Posted by gbeach View Post
wonder why I didn't have a 1 volt drop before I charged. had 38.3 at batteries and 38.2 at cart input.
thanks for the input
Ohms law is the reason. (E = I x R)
1A passing through 1Ω yields 1V.

When the cart is sitting, the current flow through the white 8Ga cable (+) is only a few milliamps so the voltage drop is relatively low. While the batteries are being charged, there is several amps flowing though the same wire, so the voltage drop is proportionally higher.

The white wire may be connected to a 60A fuse, so in addition to the intrinsic resistance of the wire's copper conductor, there are 3 sets of connections and there are two sets of connections on the black wire that might have excessive resistance.
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Old 11-10-2016, 10:59 AM   #20
gbeach
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Default Re: charger not cutting off

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
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