powerdrive battery charger owner`s manual - Club Car Side
Contents
1. Model number 17935 10 17935 20 17935 30 17935 40 19770 98 CCP N 101814301 101814303 101814304 102546901 101964301 AC INPUT AC voltage 105 128 VAC acceptable range Frequency 60 Hz e POWER CONSUMPTION Max AC current amps 10 71 10 71 10 71 10 71 10 71 DC OUTPUT DC voltage VDC start of charge cycle 18 48 48 48 48 DC current amps start of charge cycle Me 17 17 17 17 DC voltage VDC end of charge cycle 60 60 60 60 60 DC current amps end of charge cycle OBC v3 0 and later 7 eu EL ae DIMENSIONS WEIGHT 10 25 in 10 25 in 10 25 in 10 25 in 10 25 in Case overall length 26 cm 26 cm 26 cm 26 cm 26 cm i 8 687 in 8 687 in 8 687 in 8 687 in 7 25 in Case overall width 22 1 cm 22 1 cm 22 1 cm 22 1 18 4 cm 9 437 in 9 437 in 9 437 in 9 437 in 9 5 in Case overall height 24 cm 24 cm 24 cm 24 cm 24 1 cm 17 ft 5 2m 17ft 5 2 17 5 2 m 171 5 2 m 17 ft 5 2 m AC cord length retractable retractable retractable retractable retractable 80 5 in 129 5 in 162 5 in 9 5 in 21 5 in DC cord length 204 5 cm 328 9 cm 412 8 cm 24 cm 54 6 cm Weight 37 0 Ib 37 7 Ib 38 2 Ib 38 2 Ib 37 7 Ib 9 16 8 kg 17 1 kg 17 3 kg 17 3 kg 17 1 kg MOUNTING CONFIGURATION Mounting Set on shelf wall mount with keyhole or hang securely from ceiling Mounting Onboa2. Battery Charger Specifications DOMESTIC POWERDRIVE CHARGER Domestic SPECIFICATIONS PowerDrive External Battery Charger Model number 17930 11 17930 18 17930 19 CCP N 101802201 101802202 101802203 AC INPUT AC voltage 105 128 VAC acceptable range Frequency 60 Hz POWER CONSUMPTION Max AC current amps 10 71 10 71 10 71 DC OUTPUT DC voltage VDC start of charge cycle 48 48 48 DC current amps start of charge cycle 17 17 17 DC voltage VDC end of charge cycle 60 60 60 DC current amps end of charge cycle OBC v3 0 and later af ad Ar DIMENSIONS WEIGHT 10 25 in 10 25 in 10 25 in Case overall length 26 cm 26 cm 26 cm i 8 687 in 8 687 in 8 687 in overall width 22 1 22 1 22 1 i 9 0 in 9 0 in 9 0 in Case overall height 22 9 cm 22 9 cm 22 9 cm 74 in 108 in 108 in cord length 188 cm 274 3 cm 274 3 cm 103 in 144 in 240 in DC cord length 261 6 cm 865 8 cm 609 6 cm i 31 0 Ib 31 6 Ib 33 0 Ib Weight 14 1 kg 14 3 kg 15 0 kg MOUNTING CONFIGURATION Mounting Set on shelf wall mount with keyhole or hang securely from ceiling Mounting Onboard secured to the vehicle PowerDrive Battery Charger Owner s Manual Page 19 Battery Charger Specifications DOMESTIC POWERDRIVE CHARGER SPECIFICATIONS Domestic PowerDrive Onboard Battery Charger
3. Place the charger AC cord so it will not be stepped on tripped over or otherwise subject to damage or stress The use of an extension cord with the onboard charger must be avoided Do not place items in the compartment where the battery charger is installed Ensure that the charger venti lation slots are unobstructed CHARGING BATTERIES 1 Connect the AC power supply cord to an AC outlet designed to provide the proper AC voltage for the charger The charger will activate automatically within 2 to 15 seconds 2 Monitor the ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depending upon the condition and depth of discharge of the batteries Slight variations in the initial charge rate may also result from AC line input voltages which are higher or lower than the nominal input voltage Higher AC line voltages increase the initial charge rate while lower AC line voltages reduce the initial charge rate 3 PowerDrive and PowerDrive Plus vehicles Monitor the ammeter for about 30 seconds Under normal operating conditions when the charger is on and the batteries are discharged the ammeter will drop to zero for 2 to 3 seconds at the beginning of each charge cycle in order to perform a self diagnostic test This test will be repeated at one hour and two hours into the charge cycle See following CAUTION and NOTE 4 IQ System vehicles At one hour and at two hours into the charge cycle the charger will s
4. An accumulation of hydrogen gas could result in an explosion WARNING Only trained technicians should repair or service the charger Contact your nearest Club Car distributor dealer Each charger should have its own dedicated 15 or 20 ampere separately protected circuit breaker or fuse single phase branch circuit in accordance with all applicable electrical codes for the location Connect the charger AC supply cord to a properly grounded three wire outlet of the proper voltage and frequency as shown on the charger Do not use an adapter to plug the charger with a three prong plug into a two prong outlet Improper connection of the equipment grounding conductor can result in a fire or an electrical shock An extension cord or electrical outlet must accept a three prong plug Extension cord should be a three wire no 12 AWG American Wire Gauge or no 14 British Standard Wire and be as short as possible no more than 12 feet 3 7 m The use of improper extension cord could result in fire or an electrical shock Do not use near fuels grain dust solvents thinners or other flammables Chargers can ignite flammable materials and vapors Do not expose to rain or any liquid Keep the charger dry Prior to servicing the charger disconnect the AC power supply cord from the wall outlet and the DC plug from the vehicle charger receptacle When the charger is on the charger DC cord may be disconnected from the vehicle receptacle slo
5. at 220 VAC setting 209 231 209 231 209 231 209 231 209 231 AC voltage acceptable range 9 d at 240 VAC setting 228 252 228 252 228 252 228 252 228 252 Frequency 50 Hz 60 Hz POWER CONSUMPTION Max AC current amps at 100 VAC 50 HZ 13 6 13 6 13 6 13 6 13 6 Max AC current amps at 100 VAC 60 Hz 12 4 12 4 12 4 12 4 12 4 Max AC current amps at 200 VAC 50 Hz 6 9 6 9 6 9 6 9 6 9 Max AC current amps at 200 VAC 60 Hz 6 3 6 3 6 3 6 3 6 3 Max AC current amps at 220 VAC 50 Hz 6 9 6 9 6 9 6 9 6 9 Max AC current amps at 220 VAC 60 Hz 97 p3 6 3 d Max AC current amps at 240 VAC 50 Hz da 99 9 9 9 39 Max AC current amps at 240 VAC 60 HZ gA 24 s DC OUTPUT DC voltage VDC start of charge cycle 48 48 48 48 48 DC current amps start of charge cycle 17 17 17 17 17 DC voltage VDC end of charge cycle 60 60 60 60 60 DC current amps end of charge cycle OBC v3 0 and later m 4 DIMENSIONS WEIGHT 11 75 in 10 25 in 10 25 in 10 25 in 10 25 in Case overall length 29 9 cm 26 cm 26 cm 26 cm 26 cm 7 25 8 687 8 687 8 687 8 687 Case overall width 18 4 cm 22 1 cm 22 1 cm 22 1 cm 22 1 cm i 9 5 in 9 0 in 9 0 in 9 0 in 9 0 in Case overall height 24 1 cm 22 9 cm 22 9 cm 22 9 cm 22 9 cm 17 ft 5 2 m 17 ft 5 2 m 17 ft 5 2 17 ft 5 2 m 17 ft 5 2 m AC cord length retractable ret
6. be recharged after 40 to 50 energy units of discharge or each night in order to avoid deep discharging the batteries Charging between rounds will also extend battery life use the CDM Communication Display Module CCP N 101831801 See Communication Display Module in the appropriate maintenance and service supplement CHECKING BATTERY CONDITION WITH AN ONBOARD CHARGER Read DANGER WARNING and CAUTIONS beginning on page 11 It is common practice for technicians to check the condition of a set of batteries after they have been charged to ensure they have received a complete charge before the vehicle is used With IQ System PowerDrive and PowerDrive Plus vehicles this is not necessary the onboard computer controls and monitors the charge cycle If any problem occurs during a charge cycle the battery warning light located above the steering col umn in the center dash panel will illuminate intermittently If the battery warning light is illuminated after a charge cycle refer to the troubleshooting chart in the mainte nance and service manual appropriate for your battery charger If you do not have this publication contact your Club Car representative If the specified test procedures identify no problems plug the AC cord into the wall outlet and let it charge until the charger shuts off automatically If a problem is found correct it and then charge the vehicle Normal voltage near the end of a charge cycle should be approximately 59 to 63
7. the proper cord or plug With charger DC output cord disconnected connect the power supply cord to an AC supply See Battery Charger Specifications on page 19 To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord with an equipment grounding conductor and a grounding type plug The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electric Code and all local codes and ordinances The use of an extension cord with the charger should be avoided If an extension cord must be used use a three conductor 12 AWG American Wire Gauge or no 14 SWG British Standard Wire Gauge heavy duty cord with ground properly wired and in good electrical condition Keep it as short as possible no more than 12 feet 3 7 m Place all cords so they will not be stepped on tripped over or otherwise subject to dam age or stress Ensure that the charger ventilation slots are unobstructed and that there is adequate ventilation CHARGING BATTERIES WARNING Do not bypass the sense lead fuse not applicable to Precedent vehicles not applicable to Page 12 PowerDrive Battery Charger Owner s Manual External Charger Installation and Operation TransPorter and Carryall 6 vehicles that do not have a charger receptacle Be sure the fuse link is clean and tight not applicable to Precedent vehicles no
8. to cover the charger Do not allow the charger to operate for more than 30 minutes at 19 or more amperes Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightening strikes NOTE Charger operation instructions in the language of the user should be printed on or permanently affixed to the top of the charger If these instructions are not found on the charger contact your Club Car representative EXTERNAL CHARGER AC POWER CONNECTION For models 20310 11 20310 18 27640 11 and 27640 18 at a minimum a 14 3 SJT cord with IEC 60320 C13 connector is reccommended for use The AC line to which the charger is to be connected must be of the proper AC input voltage for the charger and must be capable of supplying sufficient current See Battery Charger Specifications on page 19 If the battery charger is equipped with a multi position switch for variable AC input voltage the switch must be set for the correct voltage before the AC cord is connected Figure 8 See following CAUTION CAUTION Failure to set the AC input voltage selector switch to the correct voltage could result in damage to the battery charger or batteries NOTE Make sure that the AC cord provided with your charger has the proper AC plug as approved by the local code for your location If it does not contact your Club Car representative to obtain
9. 40 61 27640 68 27640 11 27640 18 27640 22 27640 28 CCP N 103976801 103976802 103976901 103976902 105073101 105073102 AC INPUT AC voltage 100 200 220 or 240 VAC x A z A gt selectable AC voltago Hasan range 95 105 95 105 95 105 95 105 95 105 95 105 AC voltage eo range 190 210 190 210 190 210 190 210 190 210 190 210 oe a ee 209 231 209 231 209 231 209 231 209 231 209 231 Ae range 228 252 228 252 228 252 228 252 228 252 228 252 Frequency 50 Hz 60 Hz e POWER CONSUMPTION Mac Ac current amps 13 6 13 6 13 6 13 6 13 6 13 6 AG Currant amps 11 8 11 8 11 8 11 8 11 8 11 8 Max AC current amps 7 0 7 0 7 0 7 0 7 0 7 0 Max AC current amps bere ayy raed 6 1 6 1 6 1 6 1 6 1 6 1 6 3 7 2 6 3 7 2 6 3 7 2 6 3 7 2 6 3 7 2 6 3 7 2 Max As current amps 5 6 6 9 5 6 6 9 5 6 6 9 5 6 6 9 5 6 6 9 5 6 6 9 Max AC current amps SO FER 5 9 5 9 5 9 5 9 5 9 5 9 Max AC current amps M EI A 52 52 5 2 52 5 2 5 2 DC OUTPUT DC voltage VDC Typical start of charge cycle 48 48 48 48 48 48 ae amps maximum start of charge 17 17 17 17 17 17 DC voltage VDC Typical end of charge cycle 60 60 60 60 60 60 end of charge cycle OBC 47 47 47 47 47 47 DIMENSIONS WEIGHT OPERATING TEMPERATURE 11 19 in 11 19 in 11 19 in 11 19 in 11 19 in 11 19 in Case overall length 28 4 cm 28 4 cm 28 4 cm 28 4 cm 28 4 cm 28 4 cm E 8 38 in 8 38 in 8 38 in
10. 48 48 DC current amps start of charge cycle 17 17 17 17 DC voltage VDC end of charge cycle 60 60 60 60 DC current amps end of charge cycle OBC v3 0 and later 4 7 4 7 4 7 4 7 DIMENSIONS WEIGHT OPERATING TEMPERATURE 10 25 in 10 25 in 10 25 in 10 25 in Case overall length 26 cm 26 cm 26 cm 26 cm i 8 687 in 8 687 in 8 687 in 8 687 in Case overall width 22 1 cm 22 1 cm 22 1 cm 22 1 cm i 9 0 in 9 0 in 9 0 in 9 0 in Case overall height 22 9 cm 22 9 cm 22 9 cm 22 9 cm 72 in 108 in AC cord length N A N A 182 9 cm 274 3 cm 103 in 144 in 103 in 144 in DC cord length 261 6 cm 865 8 cm 261 6 cm 865 8 cm i 34 8 Ib 35 3 Ib 35 Ib 35 8 Ib Weight 15 8 kg 16 0 kg 15 9 kg 16 2 kg 22F to 122F 22F to 122F 22F to 122F 22F to 122F Normal Operating Temperature 30C to 50C 30 50C 30 to 50C 30 to 50C MOUNTING CONFIGURATION Mounting Set on shelf wall mount with keyhole or hang securely x x from ceiling PowerDrive Battery Charger Owner s Manual Page 21 Battery Charger Specifications Page 22 PowerDrive Battery Charger Owner s Manual EXPORT POWERDRIVE MA Australian Xp op PowerDrive External EXTERNAL CHARGER PowerDrive External PowerDrive External SPECIFICATIONS Battery Charger Battery Charger y 9 Model number 276
11. 8 38 in 8 38 in 8 38 in Case overall width 23 3 cm 23 3 cm 23 3 cm 23 3 cm 23 3 cm 23 3 cm 9 19 in 9 19 in 9 19 in 9 19 in 9 19 in 9 19 in Case overall height 23 3cm 23 3cm 23 3cm 23 3cm 23 3cm 23 3cm 72 in 108 in AC cord length 1829 0m 2743 em N A N A N A N A 103 in 144 in 103 in 144 in 103 in 144 in DC cord length 2616 365 8 2616 365 8cm 261 6cm 365 8 S 29 Ib 32 Ib 28 Ib 31 Ib 28 Ib 31 Ib 9 13 1 kg 14 5 kg 12 7 kg 14 0 kg 12 7 kg 14 0 kg 22F to 122F 22F to 122F 22F to 122F 22F to 122F 22F to 122F 122F Normal Operating Temperature 30C to 30C to 30C to 30C to 30C to 30C to 50C 50C 50 50 50 50 MOUNTING CONFIGURATION Mounting Set on shelf wall mount with keyhole n hang securely from ceiling ONBOARD CHARGER Export PowerDrive Onboard Battery Charger Model number 19710 17790 10 17790 20 17790 30 17790 40 CCP N 101964302 101814302 101814305 101814306 102546902 AC INPUT AC voltage 100 200 220 or 240 VAC s H n selectable AC voltage acceptable range T i at 100 VAC setting 95 105 95 105 95 105 95 105 95 105 AC voltage acceptable range 5 _ at 200 VAC setting 190 210 190 210 190 210 190 210 190 210 AC voltage acceptable range M T i _ f
12. AND CSA LISTING When operated on a 120 volt 60 Hz electrical system the following PowerDrive battery chargers have been listed by Underwriters Laboratories and by the Canadian Underwriters thereby meeting the criteria of the Canadian Standards Association PowerDrive external battery charger models 17930 11 17930 18 and 17930 19 PowerDrive onboard battery charger models 17935 10 17935 20 17935 30 17935 40 and 19770 98 EU COMPLIANCE The following PowerDrive battery chargers comply with the EU Low Voltage Directive PowerDrive external battery charger models 20310 11 20310 18 18780 11 18780 18 27640 11 27640 18 27640 61 and 27640 68 10 PowerDrive Battery Charger Owner s Manual External Charger Installation and Operation AUSTRALIAN COMPLIANCE The following PowerDrive battery chargers comply with the Australian Safety Standard AS NZS 3100 2009 1 PowerDrive external battery charger models 27640 22 and 27640 28 EXTERNAL CHARGER INSTALLATION AND OPERATION DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged
13. IMITATIONS CLUB liability under this limited warranty or in any action whether based upon warranty contract negligence strict product liability or otherwise shall be the replacement or repair of a charger or component thereof that CLUB CAR deems to be defective Replacement shall mean furnishing during the applicable limited warranty period a new charger or component thereof that is identical or reasonably equivalent to the warranted product or defective component at no cost to the purchaser Repair shall mean remedying a defect in the charger or component thereof at no cost to the purchaser during the applicable limited warranty period If CLUB CAR elects to repair the charger it may provide factory reconditioned parts or components All parts and components replaced under warranty shall become the property of CLUB CAR THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REPLACEMENT OR REPAIR OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR OR DEALER OF CLUB CAR HAS THE AUTHORITY TO MAKE OR
14. IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY IN NO EVENT SHALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS RELATED TO PROPERTY OTHER THAN THE BATTERY CHARGER LOSS OF USE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Damage not resulting from a defect that occurs due to unreasonable use abuse or neglect including failure to provide reasonable or necessary maintenance accident or alteration is excluded from the limited warranty Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitations of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For further information contact WARRANTY SERVICES CLUB CAR LLC Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 Page 24 PowerDrive Battery Charger Owner s Manual
15. be recharged after 40 to 50 energy units of dis charge or each night in order to avoid deep discharging the batteries Charging between rounds will also extend battery life use the CDM Communication Display Module CCP N 101831801 See Commu nication Display Module in the appropriate maintenance and service supplement Note Appearance of receptacle Note Appearance of may vary depending on vehicle receptacle may vary Ludere depending on vehicle Figure 12 Charger Receptacle Figure 13 Incorrect Charger Cord Removal EXTERNAL CHARGER PLUG AND RECEPTACLE When inserting the DC plug into the vehicle receptacle align the raised guide on the plug with the guide slot in the receptacle and slowly push the plug straight in Figure 12 To disconnect the plug from the vehicle firmly grasp the plug not the cord Figure 13 and slowly pull plug straight out See following WARNING and CAUTION WARNING Do not rock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 12 The battery charger DC plug must be pulled slowly from the receptacle Jerking or pulling the DC cord out quickly could cause arcing that could damage the plug and receptacle and could cause batteries to explode Do not use a battery charger if the cord plug or receptacle is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning c
16. c3 POWERDRIVE BATTERY CHARGER OWNER S MANUAL Manual Number 101993811 Edition Code 0898U0313T Page 2 PowerDrive Battery Charger Owner s Manual NOTICE Club Car is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual The Club Car Limited Warranty appears at the end of this manual No other warranties express or implied are contained herein This manual contains proprietary information that is protected by copyright All rights are reserved No part of this manual may be photocopied reproduced or translated into another language without the written consent of Club Car LLC The information contained in this document is subject to change without notice Club Car LLC reserves the right to change specifications and designs at any time without notice and without the obligation of making changes to units previously sold Club Car 204658 Augusta Georgia 30917 4658 USA Telephone 706 863 3000 Service Parts Fax 706 855 7413 www clubcar com Copyright 2004 2006 2010 2012 2013 Club Car LLC Club Car and PowerDrive are registered trademarks of Club Car LLC This manual effective July 28 2003 PowerDrive Battery Charger Owner s Manual 3 Page 4 PowerDrive Battery Charger Owner s Manual TABLE OF CONTENTS Safety Details tr an eene vete eo ru wed EU de A Een re 6 General Information wise a
17. charger receptacle connect the AC power sup ply cord to an AC outlet designed to provide the proper AC voltage for the charger 2 Connect the charger DC plug to the vehicle charger receptacle located on the seat support panel Figure 12 The charger will activate automatically within 2 to 15 seconds after the DC plug is con nected See following WARNING WARNING Do not rock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 12 3 PowerDrive and PowerDrive Plus vehicles 10 to 20 seconds after the charger activates it will shut off again to run a self diagnostic program the ammeter will drop to 0 Charging will resume in a few moments ammeter will return to previous rate of charge 4 Monitor the ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depending upon the condition and depth of discharge of the batteries Slight variations in the initial charge rate may also result from AC line input voltages which are higher or lower than the nominal input voltage Higher AC line voltages increase the initial charge rate while lower AC line voltages reduce the initial charge rate 5 PowerDrive and PowerDrive Plus vehicles Monitor the ammeter for about 30 seconds Under normal operating conditions when the charger is on and the batteries are discharged the ammeter will drop to zero for 2 to 3
18. en the charger and the onboard com puter When the charger plug is plugged into the vehicle receptacle the onboard computer locks out the vehicle drive system This prevents the possibility of driving the vehicle while the charger is plugged in and potentially damaging the vehicle and charger Long Term Storage Charge IQ System PowerDrive and PowerDrive Plus vehicles with PowerDrive chargers are designed to be left connected with AC power to the charger during off season or long term storage The onboard computer will automatically activate the charger every 15 days To return the vehicle to service unplug the charger DC cord wait 15 seconds for the computer to reset and plug the charger back in See follow ing WARNING This will ensure the batteries are at their optimum charge prior to returning the vehicle to service WARNING The charger plug must be pulled slowly from the receptacle Jerking or pulling the DC cord out quickly could cause arcing and burning that could damage the plug and receptacle and could cause batteries to explode CAUTION Be sure to check the batteries and charger monthly to maintain correct battery water level and ensure the charger is operating correctly during storage POWERDRIVE ONBOARD CHARGER FEATURES Charge Interlock When the AC power cord is inserted into a wall receptacle the onboard computer locks out the vehicle drive system This prevents the possibility of driving the vehicle whi
19. er undercharging or overcharging The computer accomplishes this by detecting when the exact amount of energy necessary has been returned to the batter ies Figure 1 Domestic PowerDrive External Charger Figure2 Export PowerDrive External Charger Models 17930 11 17930 18 and 17930 19 Models 18780 11 and 18780 18 Figure 3 European PowerDrive External Charger Figure 4 Domestic PowerDrive Onboard Charger Models 20310 11 and 20310 18 Models 17935 10 17935 20 17935 30 and 17935 40 PowerDrive Battery Charger Owner s Manual Page 7 General Information Figure 5 Export PowerDrive Onboard Charger Figure 6 Domestic PowerDrive Onboard Charger Model 19770 98 AC INPUT VOLTAGE SELECTION SWITCH D PAN Figure 7 Export PowerDrive Onboard Charger Figure 8 AC Input Voltage Selection Switch Model 19710 Figure 9 Export PowerDrive External Charger Figure 10 European PowerDrive External Charger Models 27640 61 and 27640 68 Models 27640 11 and 27640 18 Page 8 PowerDrive Battery Charger Owner s Manual General Information Figure 11 Australian PowerDrive External Charger Models 27640 22 and 27640 28 POWERDRIVE EXTERNAL CHARGER FEATURES Charge Interlock PowerDrive battery charger DC plugs have three pins rather than two blades common on most stan dard charger plugs Two of these pins are the positive and negative leads as on standard chargers the third pin is a sensing lead that is the communication link betwe
20. eter will drop to zero for 2 to 3 seconds before the charge cycle continues All vehicles If the batteries are close to being fully charged the charge cycle will begin and the charge current will begin to taper within a few minutes PowerDrive Battery Charger Owner s Manual Page 15 Onboard Charger Operation ONBOARD CHARGER OPERATION DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion WARNING Only trained technicians should repair or service the charger Contact your nearest Club Car distributor dealer Each charger should have its own dedicated 15 or 20 ampere separately protected circuit breaker or fuse single phase branch circuit in accordance with all applicable electrical codes for the location Connect the charger AC supply cord to a properly grounded three wire outlet of the proper voltage and frequency as shown on the charger Do not use an adapter to plug the charger with a three prong plug into a two prong outlet Improper connection of the equipment ground
21. harger Owner s Manual Page 5 Safety Details SAFETY DETAILS WARNING This owner s manual should be read completely before attempting to use or service the charger Failure to follow the instructions in this manual could result in property damage severe personal injury or death It is important to note that throughout this manual there are statements labeled DANGER WARNING or CAU TION These special statements relate to specific safety issues and must be read understood and heeded before proceeding with procedures If any of the information printed on the cover of the charger becomes damaged has been removed or cannot be easily read replace the cover immediately to avoid possible property damage personal injury or death Contact your Club Car distributor dealer for replacement information DANGER ADANGER indicates an immediate hazard that will result in severe personal injury or death WARNING A WARNING indicates an immediate hazard that could result in severe personal injury or death CAUTION A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury or product or property damage CAUTION A CAUTION without the safety alert symbol indicates a situation that potentially could result in property damage The safety precautions listed must be followed whenever the charger is being operated repaired or serviced Specif
22. hut off in order to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge See following CAUTION and NOTE CAUTION Do not connect an external charger to the receptacle of a vehicle equipped with an onboard charger while the onboard charger is activated Charging overload will damage the onboard computer and may cause battery damage PowerDrive Battery Charger Owner s Manual Page 17 Checking Battery Condition with an Onboard Charger NOTE PowerDrive and PowerDrive Plus vehicles the batteries are in a fully charged state and the vehicle has not been driven the onboard computer will not perform the self diagnostic test All vehicles Batteries should be put on charge at the end of each day even if the vehicle has been used for only a short amount of time even if for only 10 minutes When air temperatures fall below 65 F 18 3 C batteries charged in unheated areas should be placed on charge as soon as possible after use Cold batteries require more time to fully charge New batteries will not deliver their full range until the vehicle has been driven and recharged from 20 to 50 times Vehicles should be restricted to 40 to 50 energy units of discharge or 36 holes of golf between charges until the batteries have been properly seasoned 20 to 50 charge cycles For maximum battery life Club Car rec ommends that electric vehicles always
23. ic warnings appear throughout this manual and on the charger GENERAL INFORMATION PowerDrive battery chargers are available in several different configurations for use domestically United States and internationally Figures 1 through 7 Some PowerDrive chargers are equipped with a multi posi tion switch located on the rear panel for AC input voltage selection Figure 8 The PowerDrive battery charger is automatic and has no external controls When the charger is connected there is a 2 to 15 second delay before charging begins NOTE PowerDrive and PowerDrive Plus Vehicles Shortly after charging begins the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge This will be repeated at one hour and at two hours into the charge cycle Page 6 PowerDrive Battery Charger Owner s Manual General Information IQ System Vehicles At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge The onboard computer having recorded the amount of energy consumed as the vehicle was used directs the charger to replace exactly the amount of energy needed to fully replenish the batteries The charger then shuts off automatically preventing the possibility of eith
24. ing conductor can result in a fire or an electrical shock Do not use an extension cord Do not use near fuels grain dust solvents thinners or other flammables Chargers can ignite flammable materials and vapors Do not expose to rain or any liquid Keep the charger dry Prior to servicing the charger disconnect the AC power supply cord from the wall outlet remove the battery charger from the vehicle See Onboard Charger Removal in the appropriate maintenance and service manual Never push objects of any kind into the charger through cabinet slots They may touch dangerous voltage points or cause an electrical short circuit that could result in fire or electrical shock Do not use a battery charger if the cord or plug is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death Do not operate the charger if it has received a sharp blow was dropped or otherwise damaged in any way Have worn cut or damaged power cords or wires replaced immediately Do not block or cover the charger ventilation slots The slots provide ventilation and prevent the charger from overheating Do not allow clothing blankets or other material to cover the charger Do not allow the charger to operate for more than 30 minutes at 19 or more amperes Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrica
25. l components in the charger and on the vehicle from all but direct or close lightening strikes Page 16 PowerDrive Battery Charger Owner s Manual Onboard Charger Operation ONBOARD CHARGER AC POWER CONNECTION The AC line to which the charger is to be connected must be of the proper AC input voltage for the charger and must be capable of supplying sufficient current See Battery Charger Specifications on page 19 If the battery charger is equipped with a multi position switch for variable AC input voltage the switch must be set for the correct voltage before the AC cord is connected Figure 8 See following CAUTION CAUTION Failure to set the AC input voltage selector switch to the correct voltage could result in damage to the battery charger or batteries NOTE Make sure that the AC cord provided with your charger has the proper AC plug as approved by the local code for your location If it does not contact your Club Car representative to obtain the proper cord or plug Connect the power supply cord to an AC supply See Battery Charger Specifications on page 19 To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord with an equipment grounding conductor and a grounding type plug The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electric Code and all local codes and ordinances
26. le the charger is plugged in and potentially damaging the vehicle and charger PowerDrive Battery Charger Owner s Manual Page 9 General Information Long Term Storage Charge PowerDrive chargers are designed to be left connected with AC power to the charger during off sea son or long term storage The onboard computer will automatically activate the charger every 15 days To return the vehicle to service disconnect the AC cord from the wall outlet wait 15 seconds and then plug the AC cord back in The charger will activate Allow the vehicle to complete one full charge cycle before putting it into service BATTERY WARNING LIGHT IQ System PowerDrive and PowerDrive Plus vehicles feature a dash mounted battery warning light above the steering column that when the vehicle is in operation indicates low battery voltage or when the vehicle is being charged indicates a charging problem The battery warning light is controlled by the onboard com puter See following NOTE NOTE Beginning with the 1998 model year the onboard computer LED became part of the battery warn ing light rather than being mounted in the computer itself and the warning light lens color changed from red to amber This simplifies using a Communication Display Module CCP N 101831801 to obtain data from the onboard computer When the batteries receive an incomplete charge because 1 the DC power cord is disconnected 2 AC power to charger is interrupted 3 automa
27. mputer controls and monitors the charge cycle If any problem occurs during a charge cycle the battery warning light located above the steering col umn in the center dash panel will illuminate intermittently If the battery warning light is illuminated after a charge cycle refer to the troubleshooting chart in the mainte nance and service manual appropriate for your battery charger If you do not have this publication contact your Club Car representative If the specified test procedures identify no problems plug the DC cord into the vehicle and let it charge until the charger shuts off automatically If a problem is found correct it and then charge the vehicle Normal voltage near the end of a charge cycle should be approximately 59 to 63 volts DC START CHARGE CYCLE 1 Disconnect the DC plug from the vehicle charger receptacle 2 Wait 20 seconds then reconnect the DC cord to the vehicle receptacle See following NOTE NOTE The charger will not operate unless a delay of approximately 20 seconds is observed 3 Monitor the ammeter for the charge rate PowerDrive and PowerDrive Plus vehicles If the vehicle has not been driven since the last charge cycle and the batteries are fully charged the onboard computer will not perform a self diagnostic test The charge cycle will begin and the ammeter will not drop to zero If the vehicle has been driven even if only a few feet the onboard computer will perform the self diagnostic test the amm
28. o electrical overloads including lightning beyond the control of CLUB CAR 3 Charger DC cord set with plug which is a wear item and subject to user abuse Any warranty service which includes labor during the first year must be performed by CLUB CAR or by an authorized distributor or dealer For repairs made by qualified technicians other than CLUB CAR s factory technicians or an authorized distributor or dealer CLUB CAR will provide only the replacement parts or components The PowerDrive Chargers are intended to be used by persons with knowledge of the chargers and proper charging practices and only on CLUB CAR PowerDrive System 48 PowerDrive Plus and IQ System vehicles Any other use renders the Limited Warranties expressed herein and any implied warranties null and void and same are hereby excluded Without limiting the generality of the foregoing in any way and as part of its limited warranty exclusion CLUB CAR does not warrant that the PowerDrive Charger is suitable for use in any application other than its PowerDrive System 48 PowerDrive Plus and IQ System products As in the use of any electrical device a prudent owner will read and study the charger owner s manual the electric vehicle owner s manual the operator instructions and the battery warning labels and will exercise due care in working on or around electrical devices Transportation expenses for warranty services are also excluded from this warranty WARRANTY L
29. ould result in a fire Page 14 PowerDrive Battery Charger Owner s Manual Checking Battery Condition with an External Charger property damage severe personal injury or death A CAUTION Do not connect an external charger to the receptacle of a vehicle equipped with an onboard charger while the onboard charger is activated Charging overload will damage the onboard computer and may cause battery damage The charger cord plug and receptacle are wear items and should be inspected daily Visually inspect them for cracks loose connections and frayed wiring they must be replaced when worn or damaged If charger plug or receptacle show signs of corrosion or the plug is difficult to insert or remove the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner The plug should then be inserted and removed several times to ensure ease of insertion ease of removal and good electrical contact See fol lowing NOTE NOTE If the warning tag has been damaged or removed from the DC cord have it replaced immediately CHECKING BATTERY CONDITION WITH AN EXTERNAL CHARGER Read DANGER WARNING and CAUTIONS beginning on page 11 It is common practice for technicians to check the condition of a set of batteries after they have been charged to ensure they have received a complete charge before the vehicle is used With IQ System PowerDrive and PowerDrive Plus vehicles this is not necessary the onboard co
30. ractable retractable retractable retractable 21 5 in 80 5 in 129 5 in 162 5 in 9 5 in DC cord length 54 6 cm 204 5 cm 328 9 cm 412 8 cm 24 cm Weight 37 0 Ib 37 0 Ib 40 5 Ib 40 6 Ib 40 6 Ib 16 8 kg 16 8 kg 18 4 kg 18 4 kg 18 4 kg MOUNTING CONFIGURATION Mounting Onboard secured to the vehicle e PowerDrive Battery Charger Owner s Manual Page 23 CLUB CAR LIMITED FOUR YEAR WARRANTY FOR POWERDRIVE CHARGERS CLUB CAR LLC CLUB CAR hereby warrants to the original retail purchaser that its new PowerDrive Chargers purchased from CLUB CAR or an authorized distributor or dealer will be free from defects in material and workmanship under normal use and service for a period of four years from the date of purchase subject to the terms provisions limitations and exclusions contained herein The limited warranty with respect to parts and labor only covers defects in material and workmanship for a period of four years from the date of purchase Such repair labor shall be performed only by CLUB CAR or by an authorized distributor or dealer Purchaser shall be responsible for all freight costs to and from CLUB facility LIMITED WARRANTY EXCLUSIONS THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT APPLY TO FAILURE DUE TO 1 Lack of normal maintenance services such as preventive maintenance checks and tightening loose wire connections 2 Semiconductor parts such as diodes and fuses which are vulnerable t
31. rd secured to the vehicle Page 20 PowerDrive Battery Charger Owner s Manual Battery Charger Specifications EXPORT POWERDRIVE EXTERNAL European Export PowerDrive External PowerDrive External CHARGER SPECIFICATIONS Battery Charger Battery Charger Model number 20310 11 20310 18 18780 11 18780 18 CCP N 101956201 101956202 101831503 101831504 AC INPUT AC voltage 100 200 220 or 240 VAC gt gt m selectable AC voltage acceptable range at 100 VAC setting 95 105 95 105 95 105 95 105 AC voltage acceptable range E at 200 VAC setting 190 210 190 210 190 210 190 210 AC voltage acceptable range Y z at 220 VAC setting 209 231 209 231 209 231 209 231 AC voltage acceptable range _ at 240 VAC setting 228 252 228 252 228 252 228 252 Frequency 50 Hz 60 Hz POWER CONSUMPTION Max AC current amps at 100 VAC 50 Hz 13 6 13 6 13 6 13 6 Max AC current amps at 100 VAC 60 Hz 12 4 12 4 12 4 12 4 Max AC current amps at 200 VAC 50 Hz 6 9 9 6 9 Max AC current amps at 200 VAC 60 Hz 6 3 95 93 us Max AC current amps at 220 VAC 50 Hz 6 9 6 3 6 3 Max AC current amps at 220 VAC 60 Hz 6 8 6 8 6 9 Max AC current amps at 240 VAC 50 HZ 33 a Max AC current amps at 240 VAC 60 Hz e 2i mel 3 1 DC OUTPUT DC voltage VDC start of charge cycle 48 48
32. seconds at the beginning of each charge cycle in order to perform a self diagnostic test This test will be repeated at one hour and two hours into the charge cycle See following NOTE PowerDrive Battery Charger Owner s Manual Page 13 External Charger Installation and Operation 6 IQ System vehicles At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge NOTE PowerDrive and PowerDrive Plus vehicles f the batteries are in a fully charged state and the vehicle has not been driven the onboard computer will not perform the self diagnostic test All vehicles Batteries should be put on charge at the end of each day even if the vehicle has been used for only a short amount of time even if for only 10 minutes When air temperatures fall below 65 18 3 batteries charged in unheated areas should be placed on charge as soon as possible after use Cold batteries require more time to fully charge New batteries will not deliver their full range until the vehicle has been driven and recharged from 20 to 50 times Vehicles should be restricted to 40 to 50 energy units of discharge or 36 holes of golf between charges until the batteries have been properly seasoned 20 to 50 charge cycles For maximum battery life Club Car recommends that electric vehicles always
33. t applicable to TransPorter and Carryall 6 vehicles that do not have a charger receptacle Be sure all wire connections at the receptacle are clean and tight Do not rock or bend the plug To connect the charger plug to the vehicle receptacle grasp the plug handle and push the plug straight into the receptacle Figure 12 Do not pull on the DC cord Figure 13 Do not twist rock or bend the plug To disconnect the charger plug from the vehicle receptacle grasp the plug by the handle and pull the plug straight out of the receptacle Do not connect a charger to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged in any manner or does not make a good electrical connection Fire or personal injury can result Have it replaced by a qualified service person immediately Failure to follow these instructions could result in damage to the charger cord the plug and or the vehicle receptacle Do not use a charger if any of the following conditions exist The plug is too loose or does not make a good connection The plug and receptacle feel hotter than normal during charge The plug pin or receptacle contacts are bent or corroded The plug receptacle or cords are cut worn have any exposed wires or are damaged in any way Using the charger with any of the above symptoms could result in a fire property damage personal injury or death 1 With the charger DC cord disconnected from the vehicle
34. ti ER EE A elec Mee ERAT ER NEA EFE E 6 PowerDrive External Charger 9 PowerDrive Onboard Charger Features 9 Battery Warning Light rr Mie inei E OER ehem 10 Wand CSA Listing orm xe enr E E esi ad x aay sod gie xa Ug 10 EU Compliance Genoese tebe eg or ege ebat rus Rot ce tive hand es 10 External Charger Installation and Operation 11 External Charger AC Power Connection 12 Charging Batteries a ig pees 12 External Charger Plug and Receptacle 14 Checking Battery Condition with an External Charger 15 Start Charge Cycle bodes Pew pha tat ERN eae due 15 Onboard Charger Operation rms 16 Onboard Charger AC Power Connection 17 Charging Batteries ccc hmmm 17 Checking Battery Condition with an Onboard 18 Start Charge Cycle ra moria o a ira aina tne tenes 18 Battery Charger Specifications asana aaeeea 19 Club Cai Limited Four Year Warranty for PowerDrive Chargers 24 PowerDrive Battery C
35. tic charger shut off occurs after 16 hours of operation or 4 charger malfunctions the warning light will indicate as follows The battery warning light will not illuminate if the charge is 90 or more complete The onboard com puter will retain in memory the amount of charge needed to replenish the batteries and will complete the charge during the next charge cycle When the charger DC cord is unplugged during a charge cycle the battery warning light will illuminate and remain illuminated for 10 seconds 25 seconds for Precedent vehicles if the charge is less than 90 complete but the vehicle has enough power for 60 minutes of operation This will alert the fleet operator that the vehicle may be used but that it must be charged to completion as soon as possible The battery warning light will repeatedly illuminate for 10 seconds at 4 second intervals 25 seconds at 10 second intervals for Precedent vehicles if the charger times out at 16 hours and the batteries are not sufficiently charged This indicates an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer External chargers only The battery warning light will repeatedly illuminate for 10 seconds at 4 sec ond intervals 25 seconds at 10 second intervals for Precedent vehicles during a charge cycle with the DC plug still connected if AC power to the charger is interrupted The light will go out when AC power is restored UL
36. volts DC START CHARGE CYCLE 1 Disconnect the AC plug from the wall outlet 2 Wait 20 seconds then reconnect the AC cord to the wall outlet See following NOTE NOTE The charger will not operate unless a delay of approximately 20 seconds is observed 3 PowerDrive and PowerDrive Plus vehicles Monitor the ammeter for the charge rate If the vehicle has not been driven since the last charge cycle and the batteries are fully charged the onboard computer will not perform a self diagnostic test The charge cycle will begin and the ammeter will not drop to zero If the vehicle has been driven even if only a few feet the onboard computer will perform the self diagnostic test the ammeter will drop to zero for 2 to 3 seconds before the charge cycle continues If the batteries are close to being fully charged the charge cycle will begin and the charge current will begin to taper within a few minutes 4 IQ System vehicles IQ System vehicles At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge NOTE PowerDrive and PowerDrive Plus vehicles f the batteries are in a fully charged state and the vehicle has not been driven the onboard computer will not perform the self diagnostic test Page 18 PowerDrive Battery Charger Owner s Manual BATTERY CHARGER SPECIFICATIONS
37. wly Jerking or pulling the DC cord out quickly could cause arcing and burning that could damage the plug and receptacle and could cause batteries to explode Never push objects of any kind into the charger through cabinet slots They may touch dangerous voltage points or cause an electrical short circuit that could result in fire or electrical shock Do not connect the charger to battery packs that are not compatible with the DC output voltage specified on the charger Overheating and transformer burnout will result Do not connect a stationary charger to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged or does not make a good electrical connection Fire or personal injury can result Have a qualified technician replace the parts Do not use a battery charger if the cord plug or receptacle is damaged in any way Replace worn or damaged parts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death PowerDrive Battery Charger Owner s Manual Page 11 External Charger Installation and Operation Do not operate the charger if it has received a sharp blow was dropped or otherwise damaged in any way Have worn cut or damaged power cords or wires replaced immediately Do not block or cover the charger ventilation slots The slots provide ventilation and prevent the charger from overheating Do not allow clothing blankets or other material
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