Thunderbull Chargers- Auto shutoff not working

[06z400rider]

Hey guys, I have a tech question: I have converted two different carts to 48 volts in the last couple of months- both EzGo PDS carts '06 and '07. I tried to purchase the automatic ezgo chargers (Thunderbull brand because they're cheap.) They were out of stock on EzGo chargers both times. I instead ordered a club car charger for the 48 volt powerwise and the ezgo DC cord ends. When they arrived, I cut off the club car end and installed the ezgo end with only the white and black wires plugged up. It charged fine, but it never sensed the battery pack's presence, and it was on all the time when plugged up to AC voltage, even when not plugged to the cart. I then realized I hadn't hooked up the green sensor wire inside the EzGo plug end. I hooked it up, and when I plugged it into the cart, you could hear the relay click inside the charger, like it does on a regular powerwise. I then hooked it into the AC voltage, it charged fine, but it still never shuts off, and it has been overcharging the batteries. Once voltage gets to 56, the cart won't drive unless I somehow drain the voltage a little. I.E.: turn headllights on for a few minutes, and then it takes off once voltage is below 56. I have two brand new chargers that I really cant sell to customers unless I find a way to make the automatic shutoff work on them. They are supposed to be automatic chargers, but they are set up for Club Cars, so I don't know if an EzGo relay board or something like that would enable the auto shutoff??? I know this is a very technical question, but I figure someone on here may be able to answer it... Any ideas?

 

[dougmcp]

I may be full of it here but the Club Car splits their charging system between the cart and the charger. The cart has an OBC that regulates the charging and the charger merely supplies the charge. The Ezgo chargers are a single system that has internal regulators and does not use an OBC.
I can see the CC charger charging batteries but without any control to regulate and then fianlly shut off.
IMO, I think you may need a different charger to use on the Ezgo carts.

 

[06z400rider]

I do agree that something has to change in order for it to shut off as it should. I would rather not buy a new charger when I already have two brand new ones on hand. I have spent over $600 for these two. From what I've seen, the thunderbull chargers are all very similar with only slight differences to make them cart specific. I just tore into an automatic Ezgo thunderbull charger (supposed to be auto...haven't tested it yet. We just got it in for a different cart.) I noticed that inside the DC cord end, it has the same three wires hooked up, as I was saying. I then followed it into the charger itself, and the blue signal wire was cut. It didn't go anywhere.....Hmmmm.....Only the white and black charging wires were hooked up. There must be some kind of regulation done inside by relay, timer, etc??? If so, maybe I could order just that part and install it in the new charger....

 

[dougmcp]

IMO, I'd send them back and get the correct ones before you throw more money at it.
For less than $300 each you can also get these Eagle chargers:
48v Eagle Charger

 

[MrWicked]

we use the lester charger and they are 25 or 35 amp chargers and they are around the eagle price.... never had a timer or auto shout off problem....

 

[bigdog29609]

I sell Thunderbull chargers. The 48 volt model with the Club Car plug is designed to work with an OBC. Your dealer should have told you that. It will never shut off when using it on an EZGO system.

 

[06z400rider]

Well, as I said, I modified the DC cord end, so I doubt I could send them back... I'm in the process of doing some research on the auto shutoff EzGo by Thunderbull to see what allows it to be auto on the EzGo. It may be on an auto timer or something because the signal wire from the pack is cut off before it ever goes into the charger. When I get time next week and get back to the shop, I'll check out the internal layout on the EzGo charger and see what all is different. I know that they both have transformers that put out voltge for a 48 volt cart, so it's just a matter of seeing if the same relays, voltage sensors, etc could be installed to convert it. I don't even know how easily parts can be attained, if at all. However, rather than throwing away two new 48 volt chargers, I'm going to look into it. I will probably order new Lester chargers for these carts, and I will let you guys know how the project turns out, if anyone cares.

 

[tazassape]

Well?....................... It's kinda like reading a book only to find out the last page is missing. I'm curious to know how it turned out.

 

[06z400rider]

Well, Taz, I've been in Chicago with the wife on vacation, and I have had a ton going on lately. I bought new chargers and have kinda put this project on the back burner for a couple of weeks. I will pursue it when I get time in a week or two, though. Sorry!