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Unread 04-15-2019, 11:10 PM   #111
Not Yet Wild
Club Car
 
Join Date: Mar 2018
Location: Indianapolis, Indiana
Posts: 48
Default Re: Charging System Troubleshooting

Sergio, I'm not sure you will see this old of a post, but here goes.
I have been having OBC issues, specifically, the OBD sometimes will not activate the 48 volt relay in the PowerDrive charger. I can take a battery pack meter reading and each time it shows I have 49 volts available. I did a meter reading inside the charger case and some times there isn't any voltage at the relay and some times there is. I can use jumper leads to jump start this relay from my main 48v pack, so I know it works. A meter check at the charge plug receptacle, on the cart shows both fuses to be good, but no power from the grey wire (OBC). If I use a jumpered PowerDrive charger with the relay wired around, I can add an hour of charge to the battery pack and then re-attach the standard non jumpered PowerDrive charger, the charger will kick on the relay (50v on the grey OBD wire) thus I am able to complete a charge sesion.
The odd thing is the yellow Club Cart battery light will blink one short and one long sequence the next time we use the cart.
Which it is saying we had a incomplete or faulty charge session. The batteries are new and never go below 48v and are charged up to 52v each time we use the cart. I have followed the OBD reset procedure and it doesn't seem to help.
I noticed in your post that you suggest that my main pack ground post shouldn't have any other grounds attached ahead of the OBD. One wire only from this battery ground, to the OBD. All of my inverter grounds (lights, battery gage, ect), should be on the B- terminal of the controller? I currently have all of these ground wires on a terminal strip, which is then routed to the #6 negative battery post along with the OBD wire. I can wire this negative terminal strip directly to the B- negative post of the controller if you think that this will stop the OBD / PowerCharger relay flakiness
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Unread 04-16-2019, 08:15 AM   #112
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Club Car
 
Join Date: Sep 2012
Location: Charlotte, NC
Posts: 6,586
Default Re: Charging System Troubleshooting

You should move the negatives to the Controller B-, that is necessary so that the OBC can account for the current being used by the accessories.

As far as resetting the OBC, the only procedure needed (and effective) is to disconnect the pack negative for over 10 minutes, there is no need to move switches or press the pedal.

If You have not cleaned the charger receptacle, you can perform all 3 tasks at one time:
Disconnect the pack negative cable.
Move Your negative wires to Controller B-.
Put some WD40 on the cart charger receptacle and insert and remove the charger plug several times in order to clean the inside of each socket and pin.
Connect the pack negative wire again.
If You want to avoid a spark when you connect the pack negative cable back, just use an incandescent light bulb in series with the cable for a few seconds before touching the cable directly to the battery post.

Light bulb base touching the battery post and cable touching the bulb threads for 5sec then place cable on battery post.
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Unread 04-18-2019, 11:13 PM   #113
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Join Date: Mar 2018
Location: Indianapolis, Indiana
Posts: 48
Default Re: Charging System Troubleshooting

Sergio, Thanks for the tip. I will order some 10ga wire and move that lead from the #6 battery, to the B- on the controller. Will let you know
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