Replaced charger cord, cart won't charge

DennisWitt

2005 Club Car Precedent charger connector failed so I ordered a new one from Amazon. New cable and connector had black, white and red wires while the original cable had black, blue and red. Foolishly didn't check continuity first and reversed the connections on red and white wires. Plugged into my cart and nothing happens. No smoke or anything like that, just no charge initiated. Subsequently disassembled cable and check continuity, wired correctly and still cart won't charge. Connected charger to my other cart and it charged with no problem. So, did I kill my cart? Maybe the OBC? I plan to do OBC reset today. If that doesn't work, can I do OBC bypass with out long term damage?
Thanks in advance for your thoughts.
Dennis

BGW

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crash test dummy

try the reset
if it does not work try the by-bass on the cart
if charger works then OBC is bad
you can ether replace the OBC or get a DPI charger

the by pass is for testing only
charger will not shut off and if not monitored it will cook your batteries

Sergio

Unfortunately You most likely blew the sense wire control transistor inside the OBC.

The power drive3 uses a TVS instead of a regular flyback diode on the relay coil, so the reverse polarity on the relay coil circuit would not have affected the ability of the charger relay to activate.

Once the charger relay activated, there would have been a direct short between the +48v output of the charger and the "Sense" wire activation circuit.

You can by-pass the OBC using the procedures outlined in the stickies, but You will also need a new charger as the PowerDrive3 box does not wok without the OBC.

DennisWitt

Thanks for confirming my worst fears...

DennisWitt

One detail....the charger I have is the PowerDrive2. Any chance that makes difference?
Also, to confirm what I think I need if the OBC is cooked... I'll need to buy a DPI charger, the 17 amp version? And to get that to work, I'll need to do the OBC bypass?
Thanks so much! You guys are incredible!
Dennis

crash test dummy

try the cart by pass first ... but you said charger is good on another cart
no difference in powerdrive 2 or 3
yes the DPI charger is the best
yes the bypass is very simple

Sergio

Unfortunately the PowerDrive2 would either burn the OBC activation circuit, or in the Precedent case, blow the "Service proof" fuse inside the OBC sense circuit as soon as You plugged it into the cart.

If You look at the PowerDrive2 wiring diagram attached, if You reverse the Red and the Blue wires on the DC plug, You would short the pack positive through the now forward biased Flyback diode directly to the sense wire circuit.

The circuit is designed to provide a 0.02Amp current path for the charger relay coil, not a direct short.

Attached Images

PowerDrive2_wiring_diagram.jpg (157.3 KB, 0 views)