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Unread 08-04-2015, 03:28 PM   #21
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Default Re: bypassing obc 96 series question

i believe 3 i will double check
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Unread 08-04-2015, 03:55 PM   #22
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Default Re: bypassing obc 96 series question

Just a thought here - you know he could have the continuously variable POT per the attached wiring diagram...it is a '96 after all.
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File Type: pdf Variable Pot.pdf (151.1 KB, 0 views)
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Unread 08-04-2015, 04:10 PM   #23
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Default Re: bypassing obc 96 series question

i will double check this also thank you guys very much if you ever need tech support on welding or plasma equipment let me know
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Unread 08-06-2015, 10:29 PM   #24
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Default Re: bypassing obc 96 series question

Well I did those tests tonight and yes I have 5k and drops down to 0 ohlms I also did the voltage test he's goes from 0-7vdc, so I installed a new obc I know have solenoid closer but still no movement I checked the bus voltage at the controller that's pack voltage. Any help is greatly appreciated
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Unread 08-06-2015, 10:58 PM   #25
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Default Re: bypassing obc 96 series question

You have already verified that controller pin #1 is getting +48v with pedal down and that the throttle signal is right.

Take the pre-charge resistor off the solenoid and wait at least a couple of minutes.

Measure the voltage on controller B+, it should be less than pack voltage as the capacitors are discharging.

Press the Pedal, the voltage should go up to pack positive indicating the solenoid is working.

Measure the voltage from controller M- to B- (positive probe on M-).

The voltage should go from +48v down to 0v as You press the pedal if the controller is working.
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Unread 08-07-2015, 07:42 AM   #26
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Default Re: bypassing obc 96 series question

yes i did check pin1 and yes 48vdc thanks i will check this today
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Unread 08-09-2015, 10:30 PM   #27
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Default Re: bypassing obc 96 series question

Ok I did those tests I do have my 48 at pin 1 with the pedal pressed so then I removed the resistor on the solenoid and measured b+ to b- it's a little less than pack voltage closer to 47vdc but the m- to b- starts at 18vdc and drops to about 8vdc when the pedal is pressed. Hopefully this ales sense to you and thanks again for your time
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Unread 08-10-2015, 09:32 AM   #28
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Default Re: bypassing obc 96 series question

With the pre-charge resistor removed, the voltage between B+ and B- should have gone down to a few volts after a few minutes.

Once the pedal was pressed and the solenoid closed, the voltage should have been pretty close to pack voltage. The voltage between B+ to B- should have remained at near pack voltage with the pedal all the way down.

If that was the case and the voltage between M- and B- was as You posted, the controller is bad.
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Unread 08-10-2015, 02:47 PM   #29
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Default Re: bypassing obc 96 series question

Ok I will swap that out tonight with a known working one and let you know the results thanks again
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