Ok this is a question about my 48v 500watt three wheel scooter there is a wire that is between the xlr charging port to the battery charging wire. without this wire my chargers blow out if I connect the battery str8 to the back of the xlr charging port. .what kind of wire is this and how do i replace it DIY style.ive read on other threads that the battery is giving the charger reverse current thats why its blowing the charger becuase the wire works as a regulator or something.how do i replace this Or is there another way to charge my 48volt battery with my 48v charger without blowing the charger?
Missing wire between charge port wire and battery charging wire. Charger blows out without wire need DIY replacment
- Thread starter D-scoots
- Start date
It might be useful to explain whether or not you have wired up a new charging port, if so what did the old port look like, and/or just how is it this "mystery wire" became disconnected in the first place?
The original charger and original port should work just fine, mystery wire and all, UNLESS they have been modified in some unknown, undescribed way.
Also, this mystery wire should have TWO ends, one going to the XLR port, and the other one to the BMS, pos or neg, with additional labels, or perhaps straight to the battery terminal, or maybe to a sensor of some kind, I do not know, I have to guess, because I cannot see the battery from here.
The original charger and original port should work just fine, mystery wire and all, UNLESS they have been modified in some unknown, undescribed way.
Also, this mystery wire should have TWO ends, one going to the XLR port, and the other one to the BMS, pos or neg, with additional labels, or perhaps straight to the battery terminal, or maybe to a sensor of some kind, I do not know, I have to guess, because I cannot see the battery from here.
Very hard to follow what the frig you are doing.
Sounds like you have a scooter, with an XLR charging port. ALSO a battery charger, which has an XLR plug, which likely came with the scooter. You should clarify this point. It is important to know if the charger you are using is actually intended to charge the unit you are charging.
Now, internally, there are TWO plugs, one white, with a red wire and a black wire, and the second one, with only a black wire? AND, both of these plugs, when connected to the XLR port, at the same time, result in the charging function WORKING, and when removing one, the black one, the charge does NOT work and the charger becomes non-functional, right?
Now, it seems like, what you want to do, is follow a procedure that does NOT work, as instead of the one that DOES work, for some strange reason?
Or do you just want to know WHY it doesn't work, in a situation other than what it was originally intended to be, which apparently is because of something that happened by magic.
Sounds like you have a scooter, with an XLR charging port. ALSO a battery charger, which has an XLR plug, which likely came with the scooter. You should clarify this point. It is important to know if the charger you are using is actually intended to charge the unit you are charging.
Now, internally, there are TWO plugs, one white, with a red wire and a black wire, and the second one, with only a black wire? AND, both of these plugs, when connected to the XLR port, at the same time, result in the charging function WORKING, and when removing one, the black one, the charge does NOT work and the charger becomes non-functional, right?
Now, it seems like, what you want to do, is follow a procedure that does NOT work, as instead of the one that DOES work, for some strange reason?
Or do you just want to know WHY it doesn't work, in a situation other than what it was originally intended to be, which apparently is because of something that happened by magic.
The chargers that I have blown out are meant for the scooter. I know that its not the chargers and I know exactly why the chargers keep blowing,its becuase the wire between the positive and negative wires on the charging port And the battery charge wire is missing.I beleave this is due to reverse current from the battery.the wire I'm talking about seems to work as a regulator or something without it the charger blows out I just want to know exactly what this wire is and how can I replace it DIY.
something must have changed between the time stuff worked and the time it didn't.
a wire is unlikely to have suddenly gone missing, unless you've removed it for some reason. If so, then that's why it's not working, and you should put it back.
the only way you could get reverse current is if something is wired backwards.
if it is wired backwards, then that means either:
--something is wrong with the charger wiring
or
--something is wrong with the battery wiring
or
--something is wrong with the charger port wiring
or
--you've removed a cable that changes the polarity of the wiring between one end and the other
If multiple chargers fail, it's probably not the charger wiring.
so:
when did the charging stop working?
what specifically occured between the charging working normally, and chargers failing instead?
knowing that will help us help you figure out what is actually causing the charger failures.
a wire is unlikely to have suddenly gone missing, unless you've removed it for some reason. If so, then that's why it's not working, and you should put it back.
the only way you could get reverse current is if something is wired backwards.
if it is wired backwards, then that means either:
--something is wrong with the charger wiring
or
--something is wrong with the battery wiring
or
--something is wrong with the charger port wiring
or
--you've removed a cable that changes the polarity of the wiring between one end and the other
If multiple chargers fail, it's probably not the charger wiring.
so:
when did the charging stop working?
what specifically occured between the charging working normally, and chargers failing instead?
knowing that will help us help you figure out what is actually causing the charger failures.
The wire didnt come with the other scooter I bought from a freind and I know for a fact that the missing wire is the reason the chargers keep blowing out I just want to know how to make a wire or to replace it or find a way to charge this 48volt 8.8ah battery which has a charge voltage of 54.6v and 422.4watt hour capacity with my charger which normally charges the scooter when the wire is on there. I dont understand why people here keep acting as if I'm trying to hide or lie about something. I just wanna charge my scooter that doesn't have a wire I need which keeps the charger from blowing I beleave you are correct its a reverse polarity wire thats missing how do i find this wire what can I find it on?
That is a key fact that we didn't know until know, and it is why we ask questions--knowing that helps us help you determine what that wire is.D-scoots said:
To know for a fact that that is the case, it means you have borrowed the missing wire from him and tested with the chargers you have, and it worked. Then the wire was removed, and it didn't work.
Otherwise, you don't truly know it is a fact.
But in any case, you'd have to check with him what that "missing wire" actually is. The only way to be certain and safe is to see what was used before, and replace it.
We can't tell you what it was, as there is not normally anything between the charger and the battery (other than a BMS, which is actually a complex electronics unit typically built into the battery itself--if that is what is missing, you'd want to get another identical unit from the battery or scooter manufacturer--a simple wire isn't a replacement).
We're not.
We're trying to help you by getting you to tell us every single detail, becuase they may all be important, and some that you hadn't and havent' told us are necessary to help you.
It is extremely common for people to ocme here and post a problem, but not give us enough details to help them. Sometimes they get angry when we ask them questions and refuse to answer, so we can't help them becuase we don't know enough to do so yet.
For instance, you did not say that you bought the scooter without that wire. Your posts so far implied the wire had been there, and charging worked, and then suddenly was not, and did not. SInce that doesn't happen, we know something happened between the time it worked and the time it didn't, and neeeded you to tell us what that was.
Now we know that it is that your friend took that wire off, for whatever reason, and you will have to find out what that wire is from him, or from the manufacturer of the scooter or battery.
If you find out that it is a simple wire, with nothing else in it, then that means it is simply connecting the positive wire of teh charger to the positive wire of teh battery. and the negative wire of teh charger to the negative wire of the battery. Then you can find a source for the connectors used on each end, and buy new ones, and make your own wire to do that. Or other methods we can work out once we know that's the case, for certain.
If you find out it is not a simple wire, and it has other things in it, you must replace it with the same thing. You migth be able to build that yourself, or you migth have to buy it.
But you must know what it was before you can replace it.
If you want to troulbeshoot the problem itself, rather than worrying about the "missing wire", then you can do that, too.
First you need a voltmeter, even a cheap one like from harbor freight or walmart or the like, to measure the voltage on the battery itself. This will also tell you the polarity of the batteyr vs the colors of it's wires. Positive is usually red, but not always.
If the battery voltage is too low, or the battery is shorted, the current draw from the charger could be so high that the charger shutsdown, or blows it's fuse, or actually fails.
If the battery voltage is too high, then current can flow from the battery into the charger, if the charger is poorly designed, and do the same thing.
In te first case, the battery would need to be replaced, as it has failed.
In the second, the charger would need to be replaced with a unit of the correct voltage for the battery that is present.
Then you can also check the voltage of the charger, and it's polarity, as well as the voltage and polarity of the wires on the connectors in your picture.
First you need a voltmeter, even a cheap one like from harbor freight or walmart or the like, to measure the voltage on the battery itself. This will also tell you the polarity of the batteyr vs the colors of it's wires. Positive is usually red, but not always.
If the battery voltage is too low, or the battery is shorted, the current draw from the charger could be so high that the charger shutsdown, or blows it's fuse, or actually fails.
If the battery voltage is too high, then current can flow from the battery into the charger, if the charger is poorly designed, and do the same thing.
In te first case, the battery would need to be replaced, as it has failed.
In the second, the charger would need to be replaced with a unit of the correct voltage for the battery that is present.
Then you can also check the voltage of the charger, and it's polarity, as well as the voltage and polarity of the wires on the connectors in your picture.
If you're not willing to actually verify stuff first as recommended, you can try whatever you want, but you risk causing a fire or destroying your battery or more chargers, or all of the above.
If it's not just a wire, but is actually some form of conversion or limiting electronics, doing what you suggest could just destroy more things.
The battery itself (or it's BMS, if any) could already *be* destroyed, if it was indeed being hooked up backwards to the charger already.
It's your stuff, so you can do whatever you want, but we can't help you unless you're willing to test stuff and get more information from your friend or the scooter manufacturer.
We don't have a magic book with all the information about everything electric.
We just have experience with a lot of different systems, which are all different. Information about one system doesn't necessarily directly apply to another.
If it's not just a wire, but is actually some form of conversion or limiting electronics, doing what you suggest could just destroy more things.
The battery itself (or it's BMS, if any) could already *be* destroyed, if it was indeed being hooked up backwards to the charger already.
It's your stuff, so you can do whatever you want, but we can't help you unless you're willing to test stuff and get more information from your friend or the scooter manufacturer.
We don't have a magic book with all the information about everything electric.
We just have experience with a lot of different systems, which are all different. Information about one system doesn't necessarily directly apply to another.
You showed a picture with TWO connectors, both unplugged.
1. HOW DID THEY GET THAT WAY?
2. ARE THEY BOTH ON THE SAME SCOOTER?
3. CAN YOU PUT THEM BACK WHERE THEY WERE ORIGINALLY?
You insist a wire is missing. Yet you show two unplugged wires. Which one do you think is missing?
Did you get the charger, meant for the scooter, along with the used scooter and have you used that one for that scooter and no other?
Are the two scooters IDENTICAL? Not similar, but absolutely IDENTICAL?
When you state the charger "blew", describe in detail what exactly you mean. Light changes color, you hear a click and the fan stops, alarm beep, or smoke and flame come from the unit? Does the charger work again after it "blows", or do you now have no working charger? You have suggested that you have blown the charger more than once, you should only have two, so please explain what EXACTLY is happening.
If your original scooter is working, AND the two are identical, THEN post some pictures showing the two wires from the picture, on the working scooter, most ESPECIALLY following each end of the wire, to the battery and to the charging port. Then take the SAME pictures for the non-working unit, and we can compare the differences. The usefulness of this will depend on the above answer about the units being IDENTICAL.
WE have no freaking clue what you have, what you have done, what you are seeing, and what your problem could possibly be. WE CAN NOT SEE YOUR UNIT FROM HERE. You have left out a LOT of important information. LOTS of people insist they are certain what the problem is, and are very often wrong.
Now, you have been asked several questions which you have failed to answer. No one gets paid to help you here. Pony up on your end of the job, or most will lose interest if you are not willing to put forth the effort to solve your own problem.
1. HOW DID THEY GET THAT WAY?
2. ARE THEY BOTH ON THE SAME SCOOTER?
3. CAN YOU PUT THEM BACK WHERE THEY WERE ORIGINALLY?
You insist a wire is missing. Yet you show two unplugged wires. Which one do you think is missing?
Did you get the charger, meant for the scooter, along with the used scooter and have you used that one for that scooter and no other?
Are the two scooters IDENTICAL? Not similar, but absolutely IDENTICAL?
When you state the charger "blew", describe in detail what exactly you mean. Light changes color, you hear a click and the fan stops, alarm beep, or smoke and flame come from the unit? Does the charger work again after it "blows", or do you now have no working charger? You have suggested that you have blown the charger more than once, you should only have two, so please explain what EXACTLY is happening.
If your original scooter is working, AND the two are identical, THEN post some pictures showing the two wires from the picture, on the working scooter, most ESPECIALLY following each end of the wire, to the battery and to the charging port. Then take the SAME pictures for the non-working unit, and we can compare the differences. The usefulness of this will depend on the above answer about the units being IDENTICAL.
WE have no freaking clue what you have, what you have done, what you are seeing, and what your problem could possibly be. WE CAN NOT SEE YOUR UNIT FROM HERE. You have left out a LOT of important information. LOTS of people insist they are certain what the problem is, and are very often wrong.
Now, you have been asked several questions which you have failed to answer. No one gets paid to help you here. Pony up on your end of the job, or most will lose interest if you are not willing to put forth the effort to solve your own problem.
Gonna engage in some idle speculation here, based on extremely limited information and some educated guesses.
We have what appears to be a set, one red, one black, of charge, or discharge wires, ending, on ONE end, in a modular plug. Then we have a second wire, a single black wire, also ending, on ONE end, in a modular plug.
The red/black pair, most likely, connects the XLR plug to the battery, or battery controller board, or BMS. Hard-wired or soldered or crimped on one end, plug on the other.
The single black wire? Well, most XLR have three pins, could be a ground wire. Most chargers I have seen do not require a ground wire, though some could. Unit designed for senior citizens, maybe a safety feature?
However, the picture shows the two wires coming from different directions, though no indicator of scale and this could be misleading. I would think the plug is on the BMS or battery end, with the charging port permanently soldered, but certainly could be the other way around.
Could this be a ground wire, required by the BMS, which is soldered to the frame at some point? Or soldered to the BMS with a plug on the frame itself?
Kinda hard to imagine the whole wire would be missing, though idiots do abound.
Possible these are different models, one unit requires a ground wire and the other doesn't, connecting wrong charger first blew the BMS, which then blew the second, correct charger?
Also possible one unit is 36 volt, the other 48, or 50.4 and 54.6, connecting the wrong charger blew the BMS which in turn blew the second charger, as above.
One other thing to note: There is no such thing as a "reverse polarity wire". This is not the Starship Enterprise, reversing polarity is a mistake or screw-up, not an optional feature so Mr. Scott can solve an emergency.
We have what appears to be a set, one red, one black, of charge, or discharge wires, ending, on ONE end, in a modular plug. Then we have a second wire, a single black wire, also ending, on ONE end, in a modular plug.
The red/black pair, most likely, connects the XLR plug to the battery, or battery controller board, or BMS. Hard-wired or soldered or crimped on one end, plug on the other.
The single black wire? Well, most XLR have three pins, could be a ground wire. Most chargers I have seen do not require a ground wire, though some could. Unit designed for senior citizens, maybe a safety feature?
However, the picture shows the two wires coming from different directions, though no indicator of scale and this could be misleading. I would think the plug is on the BMS or battery end, with the charging port permanently soldered, but certainly could be the other way around.
Could this be a ground wire, required by the BMS, which is soldered to the frame at some point? Or soldered to the BMS with a plug on the frame itself?
Kinda hard to imagine the whole wire would be missing, though idiots do abound.
Possible these are different models, one unit requires a ground wire and the other doesn't, connecting wrong charger first blew the BMS, which then blew the second, correct charger?
Also possible one unit is 36 volt, the other 48, or 50.4 and 54.6, connecting the wrong charger blew the BMS which in turn blew the second charger, as above.
One other thing to note: There is no such thing as a "reverse polarity wire". This is not the Starship Enterprise, reversing polarity is a mistake or screw-up, not an optional feature so Mr. Scott can solve an emergency.
There are two wires in each of those connectors in the battery.zip file. The second wire in the black connector on the right is a bit harder to see, but it's there, and is either red or orange.AngryBob said:
Unfortunately as you note, we have no way of knowing what those wires go to or are for, until the starter of this thread checks with his friend to find out exactly what this "missing wire" actually is.
Amber, are you sure?
Zooming way in I can make out what appears to be a stub or remnant piece that could be orange or red right at the plug end but nothing beyond that point and it appears to terminate immediately at the back of the connector. Looks to me like a wire that was cut or possibly torn off right at the plug.
I see no further evidence of a second wire along the length of the existing black one.
However my eyesight is nowhere near what it used to be.
Zooming way in I can make out what appears to be a stub or remnant piece that could be orange or red right at the plug end but nothing beyond that point and it appears to terminate immediately at the back of the connector. Looks to me like a wire that was cut or possibly torn off right at the plug.
I see no further evidence of a second wire along the length of the existing black one.
However my eyesight is nowhere near what it used to be.
neither wire is clearly visible because of the black heatshrink (or other tubing) that covers almsot all of what's in teh pic up to the last maybe 1/16" or so just prior to the connector.
