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Unread 12-15-2016, 04:02 PM   #11
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Default Re: Simple Test for OBC

Make sure the AC outlet You are plugging the charger has Power.

You can make a few quick voltage tests to determine the charging problem:

Set the meter to DC Volts (200v scale if not auto-scale).


Measure from Positive Socket on the charger receptacle to Pack Negative.
You should have pack voltage.
If Not, make sure the 10ga red wire from the charger receptacle is connected to pack positive battery post.

Measure from Positive Socket on charger receptacle to Sense Wire Socket on the charger receptacle.
You should have about 42v (this can vary depending on your meter's impedance).
If Not, check the sense wire connection (and inline fuse if available) on charger receptacle.
If sense wire is good, the OBC activation circuit has failed.

Measure from Pack Positive to Negative Socket on the charger receptacle.
You should have a few volts less than pack voltage.
If Not and the cart is a DS, check the charger receptacle fuse on the negative wire (#6 on diagram below):
http://www.buggiesgonewild.com/attac...receptacle.jpg
Otherwise the SCR inside the OBC that controls the charging current has failed.


If all of those voltages are OK and the charger relay is not clicking once You plug the DC cord into the cart, the issue is on the charger side of the relay circuit (DC plug, cable or wiring connections).
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Unread 12-15-2016, 04:02 PM   #12
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Default Re: Simple Test for OBC

Do you know that there is a fuse in the charging circuit.
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Unread 12-15-2016, 11:19 PM   #13
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Default Re: Simple Test for OBC

Quote:
Originally Posted by Sergio View Post
Make sure the AC outlet You are plugging the charger has Power.

You can make a few quick voltage tests to determine the charging problem:

Set the meter to DC Volts (200v scale if not auto-scale).


Measure from Positive Socket on the charger receptacle to Pack Negative.
You should have pack voltage.
If Not, make sure the 10ga red wire from the charger receptacle is connected to pack positive battery post.

Measure from Positive Socket on charger receptacle to Sense Wire Socket on the charger receptacle.
You should have about 42v (this can vary depending on your meter's impedance).
If Not, check the sense wire connection (and inline fuse if available) on charger receptacle.
If sense wire is good, the OBC activation circuit has failed.

Measure from Pack Positive to Negative Socket on the charger receptacle.
You should have a few volts less than pack voltage.
If Not and the cart is a DS, check the charger receptacle fuse on the negative wire (#6 on diagram below):
http://www.buggiesgonewild.com/attac...receptacle.jpg
Otherwise the SCR inside the OBC that controls the charging current has failed.


If all of those voltages are OK and the charger relay is not clicking once You plug the DC cord into the cart, the issue is on the charger side of the relay circuit (DC plug, cable or wiring connections).
Sergio,
I have checked and believe all readings are as you stated they should be in each of the measurements above, how ever I will go through it once more in the morning. I have also tested the charger receptacle fuse, although I did not unbolt it to test continuity. Would that give me a faulty test result?

As you state in your last sentence, "the issue is on the charger side of the relay circuit... But that does not explain why two chargers both work on my cart, and neither one of them work on the neighbors cart. Both are DS IQ carts, one 2006 one 2007.

I will also try both chargers again in the morning.

Thank you,
George
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Unread 12-15-2016, 11:21 PM   #14
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Default Re: Simple Test for OBC

Quote:
Originally Posted by jjance View Post
Do you know that there is a fuse in the charging circuit.
Yes, two of the and both seem good.
Thank you,
George
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Unread 12-16-2016, 06:59 AM   #15
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Default Re: Simple Test for OBC

It would be unusual for the voltages above to be correct and the OBC not work.

Make sure you have the meter probes inside the front of charger receptacle socket when taken those readings to eliminate bad wire connections and fuses.

Please post the voltage readings You are getting.
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Unread 12-16-2016, 12:51 PM   #16
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Default Re: Simple Test for OBC

Quote:
Originally Posted by Sergio View Post
It would be unusual for the voltages above to be correct and the OBC not work.

Make sure you have the meter probes inside the front of charger receptacle socket when taken those readings to eliminate bad wire connections and fuses.

Please post the voltage readings You are getting.
Sergio,

Here is what I am getting as of right now.

Across the battery pack today is 51.6

inside charge receptacle positive/negative is 49.5

Measure from Positive Socket on the charger receptacle to Pack Negative. 51.1

Measure from Positive Socket on charger receptacle to Sense Wire Socket on the charger receptacle. 45.5

Measure from Pack Positive to Negative Socket on the charger receptacle 50.6

And the receptacle fuse checks good.

I think your note states that: Otherwise the SCR inside the OBC that controls the charging current has failed.

Thank you,
George
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Unread 12-16-2016, 01:10 PM   #17
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Default Re: Simple Test for OBC

Quote:
Originally Posted by gkcooper View Post
Measure from Pack Positive to Negative Socket on the charger receptacle 50.6

I think your note states that: Otherwise the SCR inside the OBC that controls the charging current has failed.
It looks like the SCR has failed and the OBC is not working.

Just to make sure, to reset the OBC, You need to leave the pack negative cable disconnected for more than 10 minutes.

There is nothing else You need to do and there is no buzzer sound.

After You re-connect the pack negative cable, the battery warning light will illuminate the first time You try to drive the cart, which is the indication the OBC has been reset.
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Unread 12-16-2016, 01:44 PM   #18
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Default Re: Simple Test for OBC

Quote:
Originally Posted by Sergio View Post
It looks like the SCR has failed and the OBC is not working.

Just to make sure, to reset the OBC, You need to leave the pack negative cable disconnected for more than 10 minutes.

There is nothing else You need to do and there is no buzzer sound.

After You re-connect the pack negative cable, the battery warning light will illuminate the first time You try to drive the cart, which is the indication the OBC has been reset.
Sergio,
Thank you, we are in the middle of the 10 minute disconnect period, and will get back to you.
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Unread 12-16-2016, 02:01 PM   #19
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Default Re: Simple Test for OBC

Quote:
Originally Posted by gkcooper View Post
Sergio,
Thank you, we are in the middle of the 10 minute disconnect period, and will get back to you.
Negative disconnected for 15 minutes, reconnected, light came on when trying to drive the cart.

No solenoid click or charging when plugging in the charger.

I guess we have exhausted the testing procedures.

Thank you,
George
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Unread 11-01-2018, 11:28 AM   #20
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Default Re: Simple Test for OBC

Old thread I know. But my charger doesn’t seem to be shutting off. Performed Sergio’s recommended voltage checks, my pack positive to charge post negative is 38volts, significantly less than the 52v pack charge. Ideas?
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