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Unread 08-13-2019, 09:48 AM   #1
Not Yet Wild
 
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Default 1999 48v CC DS regen2 not charging

Hello I have a 48v 99 CC DS that I just bought. The 6 batteries had been sitting for 2 years and did not try to charge them. I had 4 12v batteries available and installed them. The cart works as expected and beeps in reverse. The problem is the powerdrive charger won't turn on but I can hear a relay near the OBC click when I remove the charger from the charger receptacle. I tried another powerdrive2 charger and have the same symptoms. The cart won't beep in reverse and is in locked out mode while the charger is plugged in so the cart senses the charger is plugged in.*
Bat pack 49.10v
Bat pack +, charger receptacle - 48.84v
Bat pack +, charger sense receptacle 48.52v
Bat pack -, charger receptacle + 49.10v
Charger receptacle +, charger sense receptacle 48.54v
Charger receptacle +, charger receptacle - 48.84v
Charger receptacle -, charger sense receptacle 12v
I checked all 3 fuses good. Charger sense fuse, charger ground fuse and fuse near the OBC.

I have left the battey pack disconnected for 15 minutes to reset OBC. Battery light does not come on after I reconnect the negative amd try the cart. Maybe light is burnt.
Still not charging.

I bypassed the OBC by connecting a 12gauge wire from bat pack negative to charger receptacle negative and also sense gray wire to battery pack negative.
The charger kicked on at 10amp!
Does this mean the OBC is toast for sure? Anyone tried to repair an OBC?

Thank you and sorry for double post, I thought maybe nobody is looking at old treads.
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Unread 08-13-2019, 10:02 AM   #2
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Default Re: 1999 48v CC DS regen2 not charging

This is not a dumb question. When you placed the 4-12v batteries in the cart did the red charge wire from the charge receptacle get connected back to the pack positive terminal?
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Unread 08-13-2019, 10:27 AM   #3
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Default Re: 1999 48v CC DS regen2 not charging

Yes I did connect the red from charger receptacle to battery pack positive. If I bypass the OBC the battery pack gets charged.
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Unread 08-13-2019, 10:41 AM   #4
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Default Re: 1999 48v CC DS regen2 not charging

OBC....
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Unread 08-13-2019, 10:56 AM   #5
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Default Re: 1999 48v CC DS regen2 not charging

Sounds like the OBC has failed. Just note, with the OBC by-passed the Power Drive charger will need to be manually controlled. It will not know when to shut off.
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Unread 08-13-2019, 11:01 AM   #6
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Default Re: 1999 48v CC DS regen2 not charging

Ok thanks, I'll monitor it while charging, at what voltage should I disconnect it? Anyone as ever tried to open the OBC to fix it?
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Unread 08-13-2019, 11:54 AM   #7
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Default Re: 1999 48v CC DS regen2 not charging

I agree, bad OBC. The OEM Replacement number has changed. It used to be 101909902 but it is now AM1229201
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Unread 08-13-2019, 01:19 PM   #8
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Default Re: 1999 48v CC DS regen2 not charging

Quote:
Originally Posted by Bloup101 View Post
Ok thanks, I'll monitor it while charging, at what voltage should I disconnect it? Anyone as ever tried to open the OBC to fix it?
I have read in the past others attempt to disassemble the OBC but end up damaging it. It has been in many threads and can be found with some research. Could buy a new OBC or permanently bypass the failed one according to notes in the stickies and buy a smart charger.

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Unread 08-13-2019, 05:41 PM   #9
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Default Re: 1999 48v CC DS regen2 not charging

Quote:
Bat pack +, charger receptacle - 48.84v
Charger receptacle +, charger receptacle - 48.84v
This right here tells you the OBC has failed. The SCR inside the OBC controls the negative side of the charger and you should have something like a 10-15V drop on the receptacle compared to the pack voltage. This means something in the OBC current control circuit has failed. If the OBC were working, you would measure something like 36-38V across the Receptacle + and -.

The OBC is not able to be disassembled. It is Filled with waterproof electronics goo inside and it's nearly impossible to get all of it out to try to repair it.
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Unread 08-13-2019, 05:58 PM   #10
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Default Re: 1999 48v CC DS regen2 not charging

If it was me I would try one more thing. Follow the black wire from the charge receptacle and make sure it connects to the connection on the OBC. And check where it connects to the large black wire coming from the battery-. I believe these are all stake on and bullet connectors. Easy for them to come loose.
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