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Unread 04-15-2015, 07:13 PM   #31
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Default Re: Charger wont charge.

I used a Fluke 113 true RMS multi-meter. I placed it in V-check mode and checked it that way. It automatically switches between AC and DC. I'm not very mechanically inclined.
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Unread 04-15-2015, 07:17 PM   #32
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Default Re: Charger wont charge.

If you did this test many times and did not see the full battery voltage, your OBC is indeed bad. What is your pack voltage right now?
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Unread 04-15-2015, 07:33 PM   #33
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Default Re: Charger wont charge.

Quote:
Originally Posted by mShall View Post
I used a Fluke 113 true RMS multi-meter. I placed it in V-check mode and checked it that way. It automatically switches between AC and DC. I'm not very mechanically inclined.
That is a great meter, but in the V-Check mode, it presents a Low Impedance load to the circuit.

A regular High-Impedance meter (most variety of digital meters) has a Input Impedance greater than 10MΩ, so it draws very little current.

A high Impedance meter will not trigger the OBC circuit.

If You set Your meter to the regular DC volts scale, it will switch to High Impedance mode.

If You measure the same 2 wires, You should read about 5v less than the pack voltage and it will stay constant.

You can also set your meter to the Ohms setting and measure the resistance of the Relay coil (the terminals on the Relay that those wires connected to).

The charger relay should have about 2.5kΩ coil resistance. If You read 0L or open, the relay is bad.
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Unread 04-15-2015, 07:44 PM   #34
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Default Re: Charger wont charge.

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...and this I what happened. I touched my test meter leads to the blue and red ends of the wires pulled from the relay. My wife plugged the charger into the cart. We did this over and over about 15 times. Mostly, my meter would show around 4 volts, and then go back to 'OL'. Once it actually showed 45 volts, but I couldn't get it to do it again. Not sure if this would be the relay or the OBC, but I'm thinking the OBC.

Perhaps I should buy a new relay and one of those OBC bypass deals. Anyone know a good site where I could purchase those things?
These results are consistent with a working OBC activation circuit when tested with a Low Impedance meter.

When You first plug the meter, a small amount of current will flow from pack positive through the meter to the OBC sense wire.

You will read approximately 4-5v as a result of that current creating a voltage drop across the Low Impedance input of the meter.

The OBC then will turn on a internal transistor and bring the sense wire to 0v.

The meter at that point will read Pack voltage.

After a few seconds, the OBC will turn the transistor off as it does not sense any current flowing from the charger through the OBC hall effect sensor.

The meter will then read 0v.

You would need to disconnect the meter from the wires for more than 20 seconds to observe this sequence again.
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Unread 04-15-2015, 08:16 PM   #35
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Default Re: Charger wont charge.

Pack voltage is 47 volts. I measured the resistance in the charger relay and got 2.5 Ohms. So...that rules out the relay...I suppose.
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Unread 04-15-2015, 08:17 PM   #36
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Default Re: Charger wont charge.

So 1 and 4 checked out, did 2 and 3 check out as well?
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Unread 04-15-2015, 08:26 PM   #37
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Default Re: Charger wont charge.

Are you sure the AC outlet you are plugging the chareger to is working?
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Unread 04-16-2015, 07:13 PM   #38
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Default Re: Charger wont charge.

This is the latest. The outlet is good, putting out 122 volts. A dude at work suggested I take the 2 black wires loose from the charger relay and connect them together. Then plug it into the outlet. Prior to me trying this the charger wouldn't come on at all. Nothing.

I connected the two black wires from the relay, and plugged it in, and the charger came on. The amp needle is still laying on 0, but it is on and humming...for whatever that means. That's more than it's been doing.

You guys sure can teach a fellow who knows nothing about electronics a lot!
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Unread 04-16-2015, 11:22 PM   #39
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Default Re: Charger wont charge.

It's humming because it's getting power from the wall outlet to the transformer. It's going around the relay instead of through it like it's supposed to. It's not able to go through the relay because the golf car is either not telling the relay to close via the OBC, or the relay is bad. It's hard to tell you for sure with the multimeter putting out random numbers as you said it was doing. The reason the charger is sitting at zero amps is because it can not detect that it is plugged into a battery pack. It can not force power through the OBC unless the OBC closes the internal charging circuit and allows power to pass through it. This should happen simultaneously as the control circuit powers up the relay.
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Unread 04-17-2015, 04:13 PM   #40
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Default Re: Charger wont charge.

So...after all this it seems that its the OBC. My attempts at bypassing the OBC with a wire from the golfcart receptacle to the last neg battery terminal was fruitless as was my attempt at resetting the OBC. But that seems to be the problem.

It's only mystifying to think the man at the shop said he charged my cart with my charger all night. My cart was dead as a doornail when I dropped it off, and completely charged when I picked it up, so he definitely charged it somehow. intriguing.
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