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Unread 02-24-2015, 05:34 PM   #11
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Default Re: Cart won't charge after new controller install (DCX400)??

Quote:
Originally Posted by Sergio View Post
That makes a big difference... Have You checked the fuse in the gray sense wire near the charger receptacle?

What I was really trying to find out with my question about the cable end is what direction did you push the cable from?
Yes, tested the fuse. Not 100% sure but I think I pushed the wire through from to battery side towards the controller because it needed less wire length to go that route (honestly not 100% about this as it was very tight and tried a few times). Could I have damaged the plastic inside the OBC? Why would it make a difference which way the wire is pulled through?

Thanks
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Unread 02-24-2015, 06:00 PM   #12
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Default Re: Cart won't charge after new controller install (DCX400)??

You can make a few quick voltage tests to find the problem:

Set the meter to 200vDC.


Measure from Pack Positive to Negative Socket on the charger receptacle.
You should have a few volts less than pack voltage.
Measure from Positive Socket on the charger receptacle to Pack Negative.
You should have pack voltage.
Measure from Positive Socket on charger receptacle to Sense Wire Socket on the charger receptacle.
You should have about 42v.
If all of those voltages are OK and the charger relay is not clicking once You plug the DC cord into the cart, the issue is the charger relay.


To answer the question about why it may make a difference which way You pushed the cable, I am attaching an inside view of the OBC.

Look at the Blue core, the Hal effect sensor is located in the air gap.

The back of the PC board is the side towards the controller.

If the cable was forced from the battery side, the blue core is pressed against the PC board and not likely to move.

If the cable was pushed from the controller side, the OBC plastic casing facing the battery compartment could have allowed the blue core to shift and damage the hall effect sensor.

That would not prevent the charger relay from working, but was based on my first understanding of the issue where the charger was actually delivering 15amps but the OBC was not reading it.
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Unread 02-24-2015, 06:23 PM   #13
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Default Re: Cart won't charge after new controller install (DCX400)??

Quote:
Originally Posted by Sergio View Post
You can make a few quick voltage tests to find the problem:

Set the meter to 200vDC.


Measure from Pack Positive to Negative Socket on the charger receptacle.
You should have a few volts less than pack voltage.
Measure from Positive Socket on the charger receptacle to Pack Negative.
You should have pack voltage.
Measure from Positive Socket on charger receptacle to Sense Wire Socket on the charger receptacle.
You should have about 42v.
If all of those voltages are OK and the charger relay is not clicking once You plug the DC cord into the cart, the issue is the charger relay.


To answer the question about why it may make a difference which way You pushed the cable, I am attaching an inside view of the OBC.

Look at the Blue core, the Hal effect sensor is located in the air gap.

The back of the PC board is the side towards the controller.

If the cable was forced from the battery side, the blue core is pressed against the PC board and not likely to move.

If the cable was pushed from the controller side, the OBC plastic casing facing the battery compartment could have allowed the blue core to shift and damage the hall effect sensor.

That would not prevent the charger relay from working, but was based on my first understanding of the issue where the charger was actually delivering 15amps but the OBC was not reading it.
O.K, so I just did the quick voltage tests as mentioned above. All seem as they should except the 42V between positive socket and sense wire reads 37V.

I decided to try and reset the OBC and after doing so the charger does try itself again but only to about 10amps (not the full 15) twice then shuts off for good. It will not work or try itself again until I once again reset the OBC.

I'm really starting to think the OBC is at fault and something might have came loose when trying to get the new cable through.

If that's the case what are my options? New OBC? New charger? or ...........

Thanks again
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Unread 02-24-2015, 06:33 PM   #14
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Default Re: Cart won't charge after new controller install (DCX400)??

A DPI charger would be a big PLUS in the great white north.
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Unread 02-24-2015, 07:33 PM   #15
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Default Re: Cart won't charge after new controller install (DCX400)??

First, make sure You are not being too impatient, the DC cord needs to be unplugged for more than 20 secs for the OBC to start another charging cycle.

It does look like the OBC is detecting a fatal fault, most likely the Hal effect sensor got damaged.

The 37v is fine as that measurement is affected by the impedance of your meter.

A new smart charger like a DPI maybe the best option at this point.
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Unread 02-24-2015, 08:21 PM   #16
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Default Re: Cart won't charge after new controller install (DCX400)??

DPI charger is the way to go .. Where in ontario you from ?
Cheers!
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Unread 02-24-2015, 08:38 PM   #17
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Default Re: Cart won't charge after new controller install (DCX400)??

So, getting a smart charger eliminates the need for the OBC all together? I'm assuming its better to invest in a new charger over a new/used OBC. What DPI model or what other chargers would you guys recommend?

I've tried numerous time leaving minutes in between trying to reset the charge cycle. Has to be that I damaged the Hal sensor......Just when I thought I had everything back to normal.

Thanks
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Unread 02-24-2015, 09:20 PM   #18
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Default Re: Cart won't charge after new controller install (DCX400)??

Have you tried bypassing the obc and see if it charges?
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Unread 02-24-2015, 09:21 PM   #19
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Default Re: Cart won't charge after new controller install (DCX400)??

Check Scotty b carts unlimited.
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Unread 02-24-2015, 09:59 PM   #20
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Default Re: Cart won't charge after new controller install (DCX400)??

There are two DPI chargers for the 48v Club Car. One is for a CC w/o an OBC and another is for a CC with an OBC. Since you will be removing the OBC you need the w/o OBC version.
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