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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV. |
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03-31-2018, 04:11 PM | #1 |
Not Yet Wild
Join Date: Mar 2018
Posts: 4
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Total Charge III Problem
Hello golf cart guru's. I was working on my fathers EZGO Marathon today and installed a new circuit board in his Total Charge III charger (36v). Plugged it into the 110 outlet (it stayed off) and then plugged it into his cart. It came on fine and showed it was charging.
I then unplugged the cart and the charger did not cut off. Not good. The new circuit board has a red LED on it which lights when it see voltage from the cart. It too stayed on when disconnected from the cart. I unplugged the charger from the 110 and then plugged it back in and it remained off. Plugged the cart back in and the charger came on. Unplugged the cart and again the charger stayed on. I suspect a leaky diode back feeding the board making it think it's still connected to the cart. Has anyone else experienced this and am I on the right track? TIA |
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04-01-2018, 01:37 PM | #2 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: Total Charge III Problem
The board has to see the battery pack is above about 30V to turn charger on, but to turn it off, the board has to see 45V +/- 1.0V.
The turn on part of the board appears to be working, but the turn off part isn't, OR the charger's output voltage isn't climbing high enough to get the board to shut off the charger. What is the voltage between the Red and Black wires connected to the control board when the charger is on and disconnected from cart? |
04-01-2018, 02:13 PM | #3 |
Not Yet Wild
Join Date: Mar 2018
Posts: 4
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Re: Total Charge III Problem
I'll get back to you on that. Heading over there in a little while and I'll take the multimeter. I wanted to test the diodes anyhow.
I didn't let it try to complete a charge cycle. I figured if it wouldn't shut off on it's own when I unplugged it from the cart, there was a chance it could fry the batteries. |
04-01-2018, 02:16 PM | #4 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: Total Charge III Problem
Here's the manual.
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04-01-2018, 06:07 PM | #5 |
Not Yet Wild
Join Date: Mar 2018
Posts: 4
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Re: Total Charge III Problem
Thanks for the manual.
I plug the charger into 110 vac. Charger stays inactive. I plug the charger into the cart. Charger begins to charge. I unplug the charger from the cart. Charger does not turn off. At this time a take a reading at the red and black wires at the circuit board and it reads 40 vdc. Diodes tested good so I don't think that's the problem. But the red wire is picking up power off the heat sink which is also where the the white wire going to the cart plug is connected to the same terminal. Trying to figure out what's suppose to interrupt power out the red wire when the charger is disconnected from the cart. |
04-02-2018, 01:36 AM | #6 |
Over This Interview Is...
Join Date: Jun 2012
Location: AZ
Posts: 17,449
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Re: Total Charge III Problem
Output is only reaching 40v? The shut-off voltage is around 45v to charge a 36v pack. Time to check the capacitor next.
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04-02-2018, 09:21 AM | #7 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: Total Charge III Problem
Quote:
Attached is how to test the capacitor and transformer. 2. The Red wire between the heatsink and control board isn't interrupted. The control board is a semi-smart switch that energizes or de-energize the relay on it when certain conditions are met. The relay contacts connect or disconnect AC power to the transformer primary, that is what turns the charger on and off. When the charger is setting on the bench not connected to anything, the relay is de-energized and plugging the charger into a AC wall outlet does not turn it on. When the output cable is plugged into the cart the cart's battery pack voltage is felt in the heatsink. If the battery pack voltage is high enough (about 30V), the battery pack voltage energizes the relay, which in turn applies AC power to the transformer and the output of the diodes is also applied to the heatsink, making it a self holding relay circuit. The relay stays energized until the voltage on the heatsink climbs to the voltage needed to trigger the control board into de-energizing the relay. If the voltage never reaches the trigger voltage or the voltage comparator that is supposed to trigger the shutdown fails, there is a backup time on the control board that shuts the charge off after 12 to 16 hours. |
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04-02-2018, 05:01 PM | #8 |
Not Yet Wild
Join Date: Mar 2018
Posts: 4
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Re: Total Charge III Problem
Thank you for all the good information and taking the time to share it with me. I'll get back over there and do some more testing and see if (with your information above) I can figure it out. I'll update as things progress.
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04-04-2018, 06:00 AM | #9 |
Not Yet Wild
Join Date: Feb 2017
Posts: 2
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Re: Total Charge III Problem
I am having a similar issue with my Total Charg III. Being new to all this started trying to see if just parts would fix this expensive charger if replaced.
Mine did not show any amps on meter and made a different sound then usual when it was plugged into cart. Did not find this post to check voltages. Replace control board, but still no ammeter meter reading, and different sound, and took a while to shut down unless unplugged. Called tech where board was purchased and he said was probably the ammeter gauge. Bypassed that and now sounds normal but shuts off after a few minutes. thinking since I just manually charged the batteries to 100% that may be why. Going to check charger voltages, but do you think the gauge may be all I need now? |
04-04-2018, 11:00 AM | #10 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: Total Charge III Problem
Quote:
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