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Unread 07-09-2009, 05:39 PM   #41
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Default Re: How does 48V 2001 Club Cart OBC function?

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Originally Posted by scubabud View Post
In essence it does the same thing that a microprocessor does on a non proprietary charger. And Club Car uses Lester Chargers without the microprocessors... Hummm... can we say MONEY was the reason?
Well, it may be true that that transfers more of the money to a part inside the Club Car - but remember:

Lester makes the OBC for Club car - so they are both profiting from the concept.

Club Car and Lester Electrical have several patents that would be quite a hindrance for other manufacturers to get around - unless they can pay a royalty to the patent holders to license their idea.

I my opinion, it was mostly done because it was a Great Idea and they could patent it!

Anyone for the razor blade or flip top beer can?
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Unread 07-09-2009, 05:58 PM   #42
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Default Re: How does 48V 2001 Club Cart OBC function?

I learned something new today. If my CC charger fails because of the OBC I'm buying a new charger and bypass the OBC completely. Probably get a better charge with the newer technology in chargers.
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Unread 07-09-2009, 06:01 PM   #43
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Default Re: How does 48V 2001 Club Cart OBC function?

In a world where in 2011 all cell phone manufacturers will standardize chargers I see no reason why CC take a totally proprietary path. Well that was 20-30 years ago but they are still debugging the OBC to newer and worst not compatible versions.
And they have well established background of fails.
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Unread 07-10-2009, 09:28 PM   #44
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Default Re: How does 48V 2001 Club Cart OBC function?

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Originally Posted by gaston View Post
In a world where in 2011 all cell phone manufacturers will standardize chargers I see no reason why CC take a totally proprietary path. Well that was 20-30 years ago but they are still debugging the OBC to newer and worst not compatible versions.
And they have well established background of fails.
Hey Gaston - If you believe the cell phone yarn, I have a bridge in Brooklyn you may be interested in.

Here in The Villages where almost every home has a golf cart, as the dominant car brand, we probably have about 15,000 personal Club Cars. Almost all have OBCs. While some have failed, I have never heard of one (anywhere) that had to be replaced due to a "bug".

Based on the Service Manual functional description of the OBCs in even the newest carts, it would appear that virtually all the old functions that still apply are retained and only some few new ones are added as the cart technology develops.

Although these are true computers, compatibility should not be much of an issue. It is not like you are going to run your 8 year old copy of Microsoft Office on them. Nor is it likely when they do break, that 1 out of 1000 (unless one is a repair shop) of us has a good spare of any year on the shelf. I would just get the replacement for the one that broke.
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Unread 07-11-2009, 02:21 PM   #45
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Default Re: How does 48V 2001 Club Cart OBC function?

This concept of the OBC is a good one due to product liability, as the electronic advance so does the function of the OBC. Speed control, charge, and speed settings making the carts have a longer life. Newer tow motors have a system that controls speed, system monitors, and yes can shut the tow motor down if involved in an accident. The last I knew the Honda Preiss has 21 computers in it.
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Unread 07-11-2009, 06:16 PM   #46
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Default Re: How does 48V 2001 Club Cart OBC function?

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I've got a cart that doesn't seem to want to stop charging, so I'm probably in the market for a new computer...
Hey wpns!
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Unread 07-11-2009, 07:58 PM   #47
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Default Re: How does 48V 2001 Club Cart OBC function?

Hey, Dr. Bob!

Had the computer in one of my carts replaced today with a "Field Kit OBC", which seems to work fine. I'll get the exact part number, but it was all they had and they claimed success in previous installations.

There are still three different part numbers for the field kits, might have to do with lead length or battery capacity (75% discharged is when the "Charge" light comes on, and that'll be different between T-875s, T-890s and T-145s anyway) or something else equally incomprehensible.
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Unread 07-11-2009, 08:46 PM   #48
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Default Re: How does 48V 2001 Club Cart OBC function?

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Originally Posted by wpns View Post
I've got a cart that doesn't seem to want to stop charging, so I'm probably in the market for a new computer...
Hey wpns!

I am surprised that the regulars with tons of practical experience did not jumped on this with some help.

I assume your cart runs normally and if so, the OBC is working at least somewhat, or you would be dead in the water. So we can concentrate on the charging cycle.

The charger is really very dumb. It responds only to control by the OBC through a control wire.

I would say the first thing to do if you can, is borrow a charger of the same model if possible, but surely a CC charger, and see if your problem is solved. If so your charger is at fault.

Or see if your charger will charge another club car of similar year to see if your charger is good.

If you can't do that, see if you can get a voltmeter set to read 50+ volts DC on the gray wire out of the charger socket inside the golf cart. Use a straight pin to pierce the insulation and connect the + voltmeter lead to it with some light jumper leads. Connect the - voltmeter lead to the most negative battery terminal under the drivers seat. The voltmeter should be low (in the range of +2 volts) to turn the battery charger on about 10 seconds after you plug the charger into the club car. It should go high (to a ~44 volts) after about 10 more seconds to cut the charger off for a second or 2. You should see the charger amps needle drop to zero at this time. Then the gray wire goes low again and the charger comes on to continue the charge.

Each time the charger goes on or off, the gray wire controls it. A CC charger has no way to turn ON except by the gray wire going low.

This presumes you have a charger designed to work with a Club Car of course, otherwise all bets are off.

If these 2 10-second tests pass, the OBC is working well so far and can control the charger.

During a normal charge. my charger cycles off at almost exactly 1 hour and 2 hours for a few seconds after start on my cart and another similar cart. I am not sure this is always the case or if it is just due to their configuration. These cycles are fast on/off/on and you have to be watching at the exact time they occur to see them. If you do, good.

If you have been working on your electrical system, near the end of the charge when there may be a few periods an hour apart, when the charger cycles off for 4 minutes, then comes back on (or terminates). I believe this is an attempt by the OBC to get a handle on the battery pack state after the OBC has had voltage removed from it and has reset it's "temporary" data.

Eventually, the OBC should turn your charger off sometime before 16 hours or at 16 hours if it has not found cause to do so earlier. If you have run the car until it shows signs of lack of power, it may require up to 16 hours to charge. If you use a voltmeter to check the pack voltage near the end of any charge, it could be in the area of 60 to 63 volts. Yes that is scary high for a nominal 48 volt battery pack, but that is what may happen. This should be during a equalization phase when only a few amps are flowing, so the batteries are not really getting fried.

The other way to see if the OBC is controlling your charger is to see if the charger current vs time follows a curve similar to the one I described in detail in a post above. Few will have the equipment to record the current as I did, but you can manually record the current on an the charger ammeter say each 10 minutes or so and see if the graph of the current vs time has the 3 phases per my plot.

I have attached a new set of plots of current (amps) and pack volts vs time representative of a charge after a 9 mile trip so you can see how the current and pack voltage relate.

The first plot shows charging current (0 to 3 mVDC represents 0 to 16Amps) vs time for 8 hours. The next picture plots battery pack voltage (51V to 62+V) over the same time. These are the sort of plots I believe you should get if you run your cart about 9 miles at say about 15 mph average and have good batteries.

Good Luck!

Last edited by DrBob; 07-11-2009 at 10:04 PM.. Reason: Reversed voltages on Gray wire to turn chgr on & off
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Unread 07-11-2009, 08:50 PM   #49
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Default Re: How does 48V 2001 Club Cart OBC function?

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Originally Posted by wpns View Post
Hey, Dr. Bob!

Had the computer in one of my carts replaced today with a "Field Kit OBC", which seems to work fine
Good deal.

I did not read this before I prepared my last reply, but maybe it will help someone else solve a OBC vs Charger problem in a manner different than normally done of the forums.
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Unread 07-11-2009, 09:37 PM   #50
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Default Re: How does 48V 2001 Club Cart OBC function?

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Originally Posted by wpns View Post
Hey, Dr. Bob!

There are still three different part numbers for the field kits, might have to do with lead length or battery capacity (75% discharged is when the "Charge" light comes on, and that'll be different between T-875s, T-890s and T-145s anyway) or something else equally incomprehensible.
If you can get to the information, what was the part number of the one they installed in your cart and who was it made by? And refresh me on what year and model CC your had it installed in. Thanks.
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