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Unread 02-24-2015, 03:26 PM   #1
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Default Cart won't charge after new controller install (DCX400)??

Installed a new controller (DCX400) along with a new set a 4 gauge cables and now tried charging for the first time and nothing happens. I plugged in the charger, needle on meter went up for a second as it always did in the past, then back down, then back up for another couple seconds, now nothing.......

Tried unplugging everything and restarting and now nothing happens at all. Checked fuses and all are good. All was fine pre controller/cable replacement.

New 4 gauge wire still goes through OBC. Do I need to try and reset OBC? Could have the OBC fried somehow?

Besides that cart is working fine

Cart is a AQ02



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Unread 02-24-2015, 03:40 PM   #2
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Default Re: Cart won't charge after new controller install (DCX400)??

Did you enlarge the opening in the OBC with a drill?
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Unread 02-24-2015, 03:44 PM   #3
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Default Re: Cart won't charge after new controller install (DCX400)??

Quote:
Originally Posted by TahoeDawgZ71 View Post
Did you enlarge the opening in the OBC with a drill?
I cut the old wire and pulled the new one through before crimping on the new end (was very, very tight). Why do you ask about a drill?

Can it not sense amprage through the new wire?
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Unread 02-24-2015, 04:48 PM   #4
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Default Re: Cart won't charge after new controller install (DCX400)??

Any modification of the cable hole can cause the OBC to fail ? is there 48v at the cart charge receptacle..... for the charger to read when plugged in?
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Unread 02-24-2015, 04:53 PM   #5
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Default Re: Cart won't charge after new controller install (DCX400)??

Since the amp meter on the charger moves up to 15+amps, the entire system is connected and working properly.

The OBC is trying to detect "ripple" current by turning the charger on and off.

The measurement is done by the Hall effect sensor inside the OBC that the cable goes through.

Was the battery side the one You crimped the new cable end?
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Unread 02-24-2015, 04:59 PM   #6
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Default Re: Cart won't charge after new controller install (DCX400)??

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Originally Posted by scottyb View Post
Any modification of the cable hole can cause the OBC to fail ? is there 48v at the cart charge receptacle..... for the charger to read when plugged in?
Getting 48.8V at the receptacle. Nothing happens to the charger when I try to plug it in the cart
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Unread 02-24-2015, 05:03 PM   #7
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Default Re: Cart won't charge after new controller install (DCX400)??

Quote:
Originally Posted by Sergio View Post
Since the amp meter on the charger moves up to 15+amps, the entire system is connected and working properly.

The OBC is trying to detect "ripple" current by turning the charger on and off.

The measurement is done by the Hall effect sensor inside the OBC that the cable goes through.

Was the battery side the one You crimped the new cable end?
The amp meter on the charger only tried for the very first time after controller/new cable install. Now it does nothing when plugging it in.

All cable are new with new ends
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Unread 02-24-2015, 05:28 PM   #8
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Default Re: Cart won't charge after new controller install (DCX400)??

Do you have the red 10GA wire connected on battery #1 along with the heavy 2 or 4ga red wire.
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Unread 02-24-2015, 05:30 PM   #9
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Default Re: Cart won't charge after new controller install (DCX400)??

Quote:
The amp meter on the charger only tried for the very first time
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?
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Unread 02-24-2015, 05:30 PM   #10
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Default Re: Cart won't charge after new controller install (DCX400)??

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Originally Posted by jjance View Post
Suprized nobody asked but do you have the red 10GA wire connected on battery #1 along with the heavy 2 or 4ga red wire.
The 10ga red wire that goes top the receptacle itself? Yes, i'm getting 48.8volts at the receptacle
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