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Unread 05-28-2015, 04:59 PM   #1
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Default Is Controller or OBC Bad

I want to start by saying great site. I am glad I found it, I think I will need a lot of help. I moved my 78 yr old father out in the sticks with me and he is bored now that i took him from his home on the golf course. He is a retired senior chief and also worked civil service as a electrician. He talked me into trying to open a lil cart repair and here I am. The 5th customer and I am stumped and he says &*$%^64345&&*^&*%^ computers and controllers. If I read the other thread right we have a 2000 DS Sepex powerdrive plus with regen2. . I was told I could jumper from the harness side of the OBC blue and white wires and I should hear the selinoid click. But we did not get the solenoid to click. So we jumpered from the B- to the bluw/white wire on the solenoid while we still jumpered from the blue and white on the OBC and the solenoid clicked/engaged. According to my diagram the pin 11 out of the controller is supposed to have supplied the ground for the solenoid, does this say that my controller is bad ? The customer stated that the OBC was bypassed due to charging. The grey wire going from the charge recepticle to the OBC was not connected. So I am not sure if the OBC was partially bypassed or completely bypassed what would be the best way to tell. Any Help GREATLY APPRECIATED. old senior chief
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Unread 05-28-2015, 07:08 PM   #2
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Default Re: Is Controller or OBC Bad

TahoeDawgz says the following "Well if you've eliminated the potentiometer that's good. Motor is new so it should be good. Sounds like you've probably got a controller or OBC issue. The OBC provides power to the control circuit of the controller. The controller won't boot up if the OBC isn't working properly. Does the reverse buzzer work? If so you can rule out the OBC and point your finger directly towards the controller."

We do not get a reverse buzzer ?? also looking at diagram I see that the neg side of reverse buzzer is going to controller(pin 10 orange wire) so now I know the controller is not supplieing
ground for solenoid(pin 11 Blue/white) or reverse buzzer. does any of this help Any Assistance greatly appreciated I have a poor sole waiting for his cart back. THANKS
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Unread 05-28-2015, 08:57 PM   #3
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Default Re: Is Controller or OBC Bad

Well I want to say the OBC is bad. because when I disconnect harness side from OBC and jumper the white wire and blue wire I can make the reverse buzzer buzz by jumping from pin 10 to ground. SO if the OBC is not supplying power to the controller it has to be bad correct ? WELL then I get the bright idea what if I plug the controller back up, and then jumper the blue and white from the harness side of OBC, and I did. however, I still do not get solenoid click, so I get another brain fart why not jumper from B- to solenoid (blue/white) while still jumping the blue and white from harness side of OBC and the controller plugged in. I did this because I see the big yellow wire going to controller thinking it is also power to the controller. I expected to get the reverse buzzer at least but I did not get anything, with key on and in run and in reverse. so is the controller bad also ? again any help will be greatly appreciated, before I blow something up.
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Unread 05-28-2015, 10:21 PM   #4
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Default Re: Is Controller or OBC Bad

I can't recall the proper bypass technique for a Regen2 OBC. I'll have to do some digging. I'm not ignoring this post. I just don't have an answer yet.
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Unread 05-28-2015, 11:05 PM   #5
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Default Re: Is Controller or OBC Bad

Wow so glad to hear that. Do you think it sounds like a bad OBC ? Thanks for taking the time. Is it to early to tell customer anything. I know the owner thinks the OBC was completely by passed, but I just don't see it. Maybe just the charger part of OBC. Because of the cut grey wire from charger recepticle and a regular 48v charger. anyway I appreciate you taking your time and helping.
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Unread 05-28-2015, 11:12 PM   #6
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Default Re: Is Controller or OBC Bad

It's very possible that the OBC is bad, but it's hard for me to tell you it's bad for sure. I hate to tell you to pay all of that money for something and you change it and it's still not working. If it was an IQ car or a series car I'd have it fixed with my hands behind my back and blindfolded, but the Regen cars are a totally different animal. I've seen every problem in the world with them. I've seen lots of bad sonic welds in the wire harnesses, controller failures, OBC failures, everything. The problem you run into with that system is that there are so many circuits that OBC relies on, it's hard to do an easy bypass on it. My recommendation would be to track down Sergio, he's an avid member of this forum and probably understands electrical better than anybody else on here. Have him study a Regen 2 diagram and see if he can tell you how to bypass that OBC. If the car still won't run after that, it's either in the controller or the wiring.
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Unread 05-29-2015, 09:34 AM   #7
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Default Re: Is Controller or OBC Bad

The Regen1 and Regen2 system were part of the OBC evolution, the system did not become stable until the IQ carts came out.

The Regen2 tow/run switch only provided power to the key switch for the warning light and controller pedal switch.

The rest of the power was controlled by the OBC internal ON/OFF circuit. Power comes in thru the Red/White (fused) wire and out to the Blue wire to the rest of the circuit.

This system interestingly did not use a "pre-charge" resistor, the power to the capacitors was also controlled by the OBC and provided to controller pin #1.

What you did to by-pass the OBC is correct as long as the OBC White wire gauge is the same as the Blue wire, otherwise you should jump the Red/White with the Blue wire.

Your tests of the reverse buzzer and solenoid unfortunately only proved that those parts are working since you provided both a direct positive and negative to each device.

One good troubleshooting thing to keep in mind with all Club Car Sepex systems is that the reverse buzzer will work regardless of the Key Switch being ON or the pedal being pressed.

The only requirements are the Tow/Run switch being on Run and the OBC not being in lockout (charger plugged in).

If after doing the OBC by-pass and with the Tow/Run on Run, if the Reverse buzzer does not go off when You put FNR on reverse, verify that You have:
+48v on Controller pin #1 Red wire.
+48v on Controller pin #5 Blue wire.
If You get +48v on those 2 pins, the controller is probably bad.

If not, I would check those "sonic welds", they can fail after so many years exposed to the environment.

I am attaching a wiring diagram for reference as well as a sample of a sonic weld.
Attached Images
File Type: jpg CC_powerdrive_plus_(regen2).jpg (482.9 KB, 0 views)
File Type: jpg Ultrasonic_Weld.jpg (167.9 KB, 0 views)
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Unread 05-29-2015, 09:46 AM   #8
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Default Re: Is Controller or OBC Bad

See. I told you.
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Unread 05-29-2015, 07:26 PM   #9
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Default Re: Is Controller or OBC Bad

OK Sergio, I can not thank you enough for the help. I will definatley be donating to the site. OK I by-passed the OBC by jumping the blue and white wire and then tried the white and red/white wire. I did get +48 volts on pins 1 and 5 both ways I jumped it, BUT no reverse buzzer. I really think I have confirmed the controller to be bad, no solenoid click, no reverse buzzer, no go, with your help, I have told the customer and I am going to shop for a controller ( CTS C36455H4D222 ) SO I am guessing that the reason the OBC does not seem like it is working is because it senses the Controller is bad and says NO GO ??
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Unread 05-29-2015, 07:45 PM   #10
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Default Re: Is Controller or OBC Bad

The OBC does the following:

1) It controls when the charger turns ON/OFF by providing negative to the gray wire on the charge receptacle.

2) It controls the charger current because the negative wire from the charger receptacle passes through an SCR inside the OBC before it goes to pack negative.

3) It turns power OFF to the rest of the system (no power on blue wire) when the charger is plugged in so You cannot drive away with the charger still plugged.

If the OBC was already by-passed as the owner told You, what kind of charger was he using?
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