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Old 09-06-2019, 09:03 PM   #1
anziosaint
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Default 2003 IQ DS powerdrive Charger will not shut off.

Charger just recently started not shutting down. Here’s the deal..... 2003 IQ with factory charger. 48v with batteries just approaching one year old. Charger has always ramped them up to approx 58-59v while charging and shut down on its own. Batteries read 51v after settling for 12 hours after charge and all 6 read 8.3-4 individually after 12 hours off charge. Just yesterday I plugged in the cart after only a couple mile ride and it charged for 30 hours!!!!! Batteries were bubbling and warm but not too hot. The charger was at 5amps when I pulled the plug? What is going on here? Is it my OBC or a relay in the charger? I thought these chargers shut down after 16hrs as a fail safe. I’me glad I happened to check in the cart when I did.
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Old 09-07-2019, 06:15 AM   #2
LabRat
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Default Re: 2003 IQ DS powerdrive Charger will not shut off.

I have always heard that the Club Car OBC chargers are "Dumb Chargers" they must be told what to do. So i would suspect the OBC as being the root cause. I believe there is a charger manual in the Club Car electric section.
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Old 09-07-2019, 05:14 PM   #3
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Default Re: 2003 IQ DS powerdrive Charger will not shut off.

Here's what I've been told. Measure your pack voltage at the batteries. Then measure the voltage at the charging plug. There should be a few volts difference between the 2 readings. If they are the same you have a shorted SCR in the OBC.
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Old 09-08-2019, 06:50 AM   #4
Hunter450
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Default Re: 2003 IQ DS powerdrive Charger will not shut off.

Quote:
Originally Posted by WalterM6 View Post
Here's what I've been told. Measure your pack voltage at the batteries. Then measure the voltage at the charging plug. There should be a few volts difference between the 2 readings. If they are the same you have a shorted SCR in the OBC.
Walter, can you be a little more specific about testing the SCR? Measuring pack voltage is easy but measuring voltage at the charging plug? Do you mean charge receptacle? When charger is charging? I think I have the same issue as the OP in that my PD charger ran for over 24 hours and I unplugged it. Never done that before.
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Old 09-08-2019, 08:04 AM   #5
WalterM6
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Default Re: 2003 IQ DS powerdrive Charger will not shut off.

Quote:
charging plug? Do you mean charge receptacle?
Yes the charge receptacle/plug with the charger unplugged from it.
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Old 09-08-2019, 11:37 AM   #6
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Default Re: 2003 IQ DS powerdrive Charger will not shut off.

Kinda sounds like a failed OBC.

The relay in the charger can stick closed but that’s usually easy to check. First, there should be a delay from plugging the charger in until it actually turns on. Usually 5-10 seconds. The “click” when the charger turns on is the relay clicking on.
If the relay is stuck in the On position the transformer in the charger has AC power all the time. Plug the charger into the AC wall outlet, but Not to the cart. The charger should make No noise. If you can hear the transformer hum, the relay is stuck on.

Another way is with the charger plugged into the cart and charging, pull apart the yellow fuse holder on the grey wire on the back of the charge receptacle. The charger should turn off. If it does Not turn off, the relay is stuck.
If the charger passes those two tests your problem is the OBC.
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Old 09-08-2019, 02:01 PM   #7
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Default Re: 2003 IQ DS powerdrive Charger will not shut off.

This from Tahoe...

When you plug the DC Cord into the cart is there a delay before the charger turns on? There should be. If ever there isn't a delay, replace the OBC. Often, when OBCs fail, they get stuck in "ON" mode and the charger turns on immediately when it makes a connection. When this happens, the charger will never turn off.
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Old 09-08-2019, 02:51 PM   #8
WalterM6
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Default Re: 2003 IQ DS powerdrive Charger will not shut off.

Quote:
If ever there isn't a delay, replace the OBC
I hate to disagree with Tahoe but...If the OBC fails replace it with a Smart Charger. My preference is the DPI Charger but there are others just as good or maybe better. The OBC is obsolete technology.
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Old 09-08-2019, 09:37 PM   #9
anziosaint
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Default Re: 2003 IQ DS powerdrive Charger will not shut off.

I have two smart chargers but also have a spare OBC that will fit the cart. Going the smart charger route would be the best move but the most expensive too. I will swap out the OBC after checking the relay in the charger first. I will post the results later this week when I get to it. Thanks for all the replies.
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Old 09-13-2019, 09:11 PM   #10
anziosaint
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Default Re: 2003 IQ DS powerdrive Charger will not shut off.

UPDATE: today I swapped out the OBC. I tested the pack volts first. The batteries have been sitting for a week off the charger. Pack was holding a reading or 50.5v next I tested the volts at the charge receptacle and got a reading of 37.4v???? I then tested the charger to make sure the relay was not stuck on which it was not. NEXT I swapped the 2004 OBC for one from a 2003. Both IQ carts and powerdrive chargers. After the swap I tested the voltage at the receptacle and it showed a reading of 49.4v. Earlier in this post someone said that the reading should be a few volts off of the pack total so I am feeling pretty good. Its 10p here so Ime heading to bed soon. The charger is running and I will check on it at approx. 5:30am and hoping it has shut off. I really am keeping my fingers crossed that that weird reading of 37.4v at the charge port is a dead giveaway that the OBC was the issue. Will update in the am.
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