I have a 2012 GEM E2 vehicle.
The original charger failed, and it is not possible to order or repair it. The original charger was a Delta-Q 912-7200 with four output wires: red, black, green, and white.
We ordered a replacement charger (72V 12A) for GEL 8G31 batteries with an Anderson plug, which only has two wires: red and black. The new charger charges the batteries properly.
The issue occurs when I try to start the vehicle—it still indicates that it is charging. I tried connecting the green wire to the red wire, and now there are multiple flashing indicators, but the vehicle is able to run.
Can you advise on how I can bypass this issue? Specifically, where should I connect the green and white wires?
Are you talking about the car side charger wires?
The green is the interlock wire. In normal operation it is connected to red B+ inside charger.
Connecting it to B+ allows car to run. Disconnecting it allows proper charging through psdm shunt.
White wire is battery thermistor.
Randomly jumping wires can cause permanent damage to car and charger.
Your new charger has these functions, 90% sure, not connected internally.
It would have been better to ask here first, then buy the correct charger.
I recommend swapping the charger end plate and 2 wire cord for your old end plate and 4 wire cord. The green and white just plug-in.
Can you be more specific on what charger you installed? It does not sound like even close to a Delta Q, but more of a generic cart charger.
Are you sure this car is a 2012? Who said it cannot be ordered or repaired? What was wrong with it? Is it still around?
Also, there are a few green wires running around. (Hopefully, you picked the correct one to do your creative wiring).
Describe it, and see if you can follow where it goes.
Also, which red wire did you connect it to?
(I am trying to determine why your display is flashing).
Installed a non-original charger (not a DELTA Q) with only two wires: red and black, and an Anderson connector. Unfortunately, ordering a new charger or sending one for repair is too complicated and expensive from my country, and it might also get held up in customs.
I left the four wires from the original DELTA Q charger connected to the vehicle: red, black, green, and white.
As for the model year, I am sure it is 2012/2013.
I would appreciate a creative solution for the green and white wires.
Again → White wire from the DQ charger it the Temperature sense wire. It normally connects to an Or/G wire that runs back to a sensor placed on a battery terminal. Since you are no longer using this charger, you no longer need this wire.
The green wire from the DQ charger is the Charger Interlock wire that tells the car systems that it is plugged in, and keeps the car from driving away. When Interlock is active a yellow plug appears on the display. Since you are no longer using the DQ charger(not plugging it in) You can simply leave that wire in place and the car will drive.
If you left the original wires in place, then you must have done something else to the car that caused the display to flash. You mentioned that you connected the green wire to the red wire? → What else/exactly did you do?
Again → What made you think the original DQ had failed?
Are you sure it is dead?
Replacing the DQ with a generic charger is not as simple as one would think.
The DQ in your car also contains the DC-DC converter. This down steps the main battery 72v to 12v for the car subsystems. Without 12v, the car will not function. If the converter is still working, you need to leave the DQ in place and wired up (which it sounds like you did).
The Interlock. - It does two things. It stops the car from driving away when charging, and it tells the digital dash the car is charging so the battery bars can keep count properly. You can bypass the interlock to drive the car, but if you need to cycle the interlock when charging, else the battery bars will not be accurate.
It is important to connect the new charger in the correct place(The same place the DQ is hooked to(Red wire to the front of the PSDM on the LEFT post, and the black wire on the front of the PSDM Right side, bottom post. If not, the Battery Bars will not be able to keep track of HOW MUCH charge was accepted and no longer be accurate.
Reset the Turtle - If you happen to drive the car long enough to deplete your battery power enough, it will set the Turtle. This sets the controller into a low power condition that limits speed and accel in an attempt to get you home. Both events 2 and 3 need to be executed to clear a turtle.
