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Unread 03-04-2015, 05:21 PM   #31
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Default Re: Cart won't charge after new controller install (DCX400)??

Either now or later You will need to run a 10ga wire from the negative on the charger receptacle directly to the pack negative battery post.

The new DPI accusense will not work without that wire.

Your existing charger is probably not charging because the wire is not in place.

What You did is just by-pass the charger relay activation, it does nothing to allow current through a bad OBC.
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Unread 03-04-2015, 09:22 PM   #32
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Default Re: Cart won't charge after new controller install (DCX400)??

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Originally Posted by Sergio View Post
Either now or later You will need to run a 10ga wire from the negative on the charger receptacle directly to the pack negative battery post.

The new DPI accusense will not work without that wire.

Your existing charger is probably not charging because the wire is not in place.

What You did is just by-pass the charger relay activation, it does nothing to allow current through a bad OBC.
Makes sense since the negative from charger is really going nowhere. So if I add the 10ga wire from negative on the charger receptacle directly to negative battery post my current charger should work until I receive the new one?
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Unread 03-04-2015, 09:33 PM   #33
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Default Re: Cart won't charge after new controller install (DCX400)??

Yep, the current should start at 15+ amps, let it run until you get over 60v and before 63v.

You should see the current drop below 4 amps after the pack reaches 60v.

The current charger will work if You leave the jumper on the sense wire in place as well.

My preference would be to run both the sense wire and the 10ga from charger receptacle to pack negative.

The DPI does not use the sense wire, but that way You would have the option to plug a regular club car charger if You ever need a backup charge, although you would still have to monitor the voltage.
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Unread 03-04-2015, 09:44 PM   #34
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Default Re: Cart won't charge after new controller install (DCX400)??

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Originally Posted by Sergio View Post
Yep, the current should start at 15+ amps, let it run until you get over 60v and before 63v.

You should see the current drop below 4 amps after the pack reaches 60v.

The current charger will work if You leave the jumper on the sense wire in place as well.

My preference would be to run both the sense wire and the 10ga from charger receptacle to pack negative.

The DPI does not use the sense wire, but that way You would have the option to plug a regular club car charger if You ever need a backup charge, although you would still have to monitor the voltage.
Great, thanks. I'll charge it up tomorrow when I can monitor the charge, would hate to fall asleep and fry the batteries. Now that my OBC is fried, can I just cut the negative wire going to it and redirect it to pack negative? Isn't that what I'm doing anyway (negative from recptacle to pack negative)
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Unread 03-04-2015, 09:55 PM   #35
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Default Re: Cart won't charge after new controller install (DCX400)??

If it reaches that would work great, just crimp a 5/16 ring terminal on it.
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Unread 03-04-2015, 10:05 PM   #36
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Default Re: Cart won't charge after new controller install (DCX400)??

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If it reaches that would work great, just crimp a 5/16 ring terminal on it.
Should reach no problem as the wire runs right past the battery all the way back to the OBC, plus that wire is already nicely soldered onto receptacle (-)
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Unread 03-06-2015, 08:31 AM   #37
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Default Re: Cart won't charge after new controller install (DCX400)??

I Need to Bypass OBC 48v on 95' Club

I did it for 6 mths and it worked, but got tired of it and bought the dpi. Post 31 says not then 33 says yes
Maybe my experience is special. I didnt try to lead ya astray yank.
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Unread 03-06-2015, 08:55 AM   #38
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Default Re: Cart won't charge after new controller install (DCX400)??

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I Need to Bypass OBC 48v on 95' Club

I did it for 6 mths and it worked, but got tired of it and bought the dpi. Post 31 says not then 33 says yes
Maybe my experience is special. I didnt try to lead ya astray yank.
What you suggested is correct if the charger relay activation side of the OBC is bad.

That would normally be a symptom that is caused by a failed diode on the Charger Relay Coil.

If the charger is working, but current is not flowing through to the batteries, then the SCR inside the OBC that controls the charger current has failed and needs to be by-passed.

If You are going to replace the OEM charging system with a smart charger, then a complete by-pass of the OBC is a must.
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