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Unread 08-19-2015, 09:57 PM   #1
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Default 48v charging/wiring question

I am almost done my limo build and went to charge my new Trojans tonight. Charger clicks but no needle movement. Tried charger on another cart and it is good. I jumped the two wires inside the charger and it stays humming but no charging on limo. Fuse on receptacle is good. Fuse in yellow case is good. First thought was obc but then I looked at battery pack and didn't see the usual wire that goes from receptacle to pack. There is only one wire that goes to the pack and I thought it was for the headlights. Could be mis wired by previous owner as it is a red wire going to a negative post. I am a bit stumped. Oh, 2001 DS series Villager 6
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Unread 08-19-2015, 11:04 PM   #2
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Default Re: 48v charging/wiring question

Charge port should have blk wire going to OBC a red wire going to pack pos. gray wire going to OBC.
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Unread 08-20-2015, 06:20 AM   #3
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Default Re: 48v charging/wiring question

I have a black and grey going to OBC but the red wire is going to the post on the solenoid that also has the red wire going to the + pack post. Is there something different on the wiring for a Villager 6?
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Unread 08-20-2015, 08:33 AM   #4
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Default Re: 48v charging/wiring question

You said you had a red wire going from charge port to pack neg. Is that correct?
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Unread 08-20-2015, 08:42 AM   #5
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Default Re: 48v charging/wiring question

I am not sure where the red wire is coming from, but it is not from the charging receptacle. I believe it powers the factory lights. This thing has a lot more going on wire wise than a regular ds.
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Unread 08-20-2015, 09:33 AM   #6
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Default Re: 48v charging/wiring question

Quote:
Originally Posted by 1970buick View Post
I am not sure where the red wire is coming from, but it is not from the charging receptacle. I believe it powers the factory lights. This thing has a lot more going on wire wise than a regular ds.
Larger Black wire from the charge port should go to the OBC that is the (-) wire.

Gray wire from the charge port should go to the OBC that is the "switch" wire.

Larger Red wire from the charge port "should" go directly to your battery pack main (+) post.

Without the above you are likely not charging till you do....
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Unread 08-20-2015, 10:23 AM   #7
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Default Re: 48v charging/wiring question

Ok, I am going to rewire it that way. Any idea on what guage wire is ideal? Don't think I have anything as thick as what's on there now.
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Unread 08-20-2015, 11:01 AM   #8
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Default Re: 48v charging/wiring question

Wires from charge port are 10 ga.
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Unread 08-20-2015, 02:29 PM   #9
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Default Re: 48v charging/wiring question

I have an identical, all stock, unmolested Villager 6 and went to look at it for reference. Here is what I found..
1. the red wire from the receptacle is wired from the factory to the solenoid and then there is a red wire from that same post to the + of the battery pack.
2. I tried jumping the gray wire from receptacle straight to - of battery pack with no change in charge status.
3. I used my DVM and tested negative at receptacle to red wire on solenoid and have 54v while charger is plugged in.
4. I used the DVM and tested from + of battery pack to negative on receptacle and get 54v
5. + of pack to - of pack reads 49.8v charger plugged in or not.

What am I missing here?
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Unread 08-20-2015, 02:35 PM   #10
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Default Re: 48v charging/wiring question

Was Your #4 test also with charger plugged in?

Disconnect the charger and measure the voltage from the + and - at the charger receptacle, You should get around +45v.

if You get 0v, either there is a connection problem between:
Charger receptacle negative -> OBC -> Controller B- -> Pack negative
Or
The SCR inside the OBC has failed.
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