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Unread 03-01-2015, 09:38 PM   #1
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Default 97 CC DS 48V- No Run

I've got 49.6 at the pack. I've passed the motor test by jumpering A1-F1 and A2-F2 and applying 12VDC.. I've validated the FNR toggle switch connections and switch functions. I've validated the sweeper microswitch and the variable resistance. I've validated the key switch. I've cleaned and triple-checked every electrical connection everywhere. I've got clicking solenoid (the one with direct B+) with key, with FNR switch, and with sweeper. I've jumpered the other solenoid (the one with the coil resistor). I've checked the fuses. I've even swapped in a controller and OBC from a different cart. This thing was running fine just a couple days ago, and now it's deader than Moses. I read here that the OBC supplies ground to one of the two solenoids, but one is working and the other is (test) jumpered. Although this cart is unmolested original, I have yet to find a schematic that matches it exactly. Even still, the logic is same, and I cannot find the flaw - unless I've stumbled upon not one, but two suddenly failed controllers. Advice greatly appreciated.
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Unread 03-02-2015, 08:46 AM   #2
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Default Re: 97 CC DS 48V- No Run

This problem may be related to your other post. The OBC would cause both problems.

The change from Powerdrive plus (Regen1) to Powerdrive plus (Regen2) happened in 1998. If You have a late 1997 model, you could have a Regen2.

Also, since Regen1 controllers are no longer available, You may have a Regen1 cart with an adapter harness to a Regen 2 controller.

1) Do You have a Tow/Run switch?

2) Is the Resistor coil for the DB solenoid on top of the solenoid or off to the side and connected by cables to the DB Solenoid?

3) Is Your Controller T-Shaped?
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Unread 03-02-2015, 10:48 AM   #3
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Default Re: 97 CC DS 48V- No Run

This may help determine the drive system type.
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File Type: jpg CC Regen I or II.JPG (115.5 KB, 0 views)
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Unread 03-02-2015, 12:35 PM   #4
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Default Re: 97 CC DS 48V- No Run

Yes, I had downloaded that good chart and had determined that my cart is a Regen 1. There is no "tow/run" switch, and the solenoid (not sure what "DB" means) has leads to the round coil resister mounted on the frame rail below. An archaic device for sure. However, even with that solenoid's large cables jumpered, I still get no run. The spare controller I swapped in was also Regen 1, and exactly same part number, but perhaps it too could be failed? Anyways, I've got the pack now coming up to full charge and will see what happens next. I've been given the blessing to spend money to make this cart healthy as we depend on it to transport guests.
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Unread 03-02-2015, 12:50 PM   #5
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Default Re: 97 CC DS 48V- No Run

FSIP makes a 300 (stock) and 500 amp (upgrade for bigger tires & heavier loads) control for this cart. We are an FSIP dealer. The install eliminates the regen solenoid. see diagram attached.
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Unread 03-02-2015, 01:10 PM   #6
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Default Re: 97 CC DS 48V- No Run

"DB" in this case stands for Dynamic Brake.

If You by-pass the DB solenoid, You must also unplug the speed Sensor, otherwise You will have a very harsh brake possibly locking the wheels.

Here is a good quality wiring diagram for your cart.

If You determined from the other post that the OBC is bad, You must also by-pass the OBC charger lockout to the controller.

In this version of the Regen1, Unplug the yellow wire bullet connector, #19 in the wiring diagram near the controller.

Run a 16ga wire from the controller side of the yellow wire directly to pack negative or controller N.
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File Type: jpg CC_powerdrive_plus_(regen1).jpg (390.3 KB, 0 views)
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Unread 03-02-2015, 10:49 PM   #7
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Default Re: 97 CC DS 48V- No Run

So, I'm thinking that "regen" and "dynamic braking" mean the same thing - yes?
Unless a miracle occurs, and this thing suddenly decides to run, a controller replacement seems in the plan. Since that will eliminate the DB solenoid, I would like to know where I unplug the speed sensor. I don't see that labelled on any of the diagrams. I understand (and will perform tomorrow) your instruction on bypassing the OBC charger lockout. Perhaps that will be the key to running again on present controller. You guys have no idea how grateful we are for all this good advice!
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Unread 03-02-2015, 11:00 PM   #8
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Default Re: 97 CC DS 48V- No Run

The speed sensor is the 3-pin connector coming off the end of the motor, just unplug it.

By-passing the OBC lockout circuit should get you running again.

To answer your question, they are similar, both turn the Motor into a generator by powering the Field coils an allowing the wheels to turn the non-energized armature.

Regen braking sends the current back to the batteries.

If the OBC determines the batteries cannot take the current, or in the case of the Regen 1 and Regen2, if the motor is not spinning fast enough, the current is dissipated through the resistor on top of the DB solenoid.

If there is no resistor to limit the current because is by-passed, it will be a violent "plug brake" kind of event.

Last edited by Sergio; 03-02-2015 at 11:06 PM.. Reason: More information
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Unread 03-03-2015, 09:24 AM   #9
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Default Re: 97 CC DS 48V- No Run

Ok, I have bypassed the OBC charger lockout as instructed (#19 controller side to terminal N), and still no run. Have tried with speed sensor connected and disconnected. I have 51.7 pack voltage. Primary soleniod activates when I turn key on. I have tried also with both solenoids jumpered and still no run. Solenoid no longer activates with sweeper, only with key. Very puzzled.
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Unread 03-03-2015, 09:51 AM   #10
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Default Re: 97 CC DS 48V- No Run

How exactly did You by-pass the Dynamic brake solenoid?

Did You run the cable from Motor A2 directly to Controller A2?

or did You put all 4 large cables on the same post?

Make sure however you did it that there is a direct connection from Motor A2 to controller A2. (and leave the speed sensor disconnected)

Any other wiring changes?
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