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Unread 05-18-2011, 10:00 AM   #81
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Default Re: How does 48V 2001 Club Cart OBC function?

Okay I just have to know what are the village's
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Unread 05-18-2011, 10:25 AM   #82
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Default Re: How does 48V 2001 Club Cart OBC function?

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Okay I just have to know what are the village's

here check this out

http://www.thevillages.com/
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Unread 05-30-2012, 04:43 PM   #83
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Default Re: How does 48V 2001 Club Cart OBC function?

Ok, I'm not sure why this thread went quiet a year ago, but maybe I can get a response from Doc Bob. I appear to have a dead OBC from a 1997 DS. I have a 3rd party automatic charger so it doesn't play a role in the charging, and I've also had to bypass the solenoid lockout as it obviously won't enable it. So, while I don't need the OBC, I would like to repair it if possible. It says 'Fused' on the unit, so maybe it's as simple as a blown internal fuse. Of course, there is the problem of it being fully potted. I was wondering if Doc Bob has done any more investigation, and managed to find the location of the 'fuse' in the unit he tore apart. That way, perhaps I can pry away enough of the potted material to expose the fuse without destroying the rest of the unit.
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Unread 05-30-2012, 05:25 PM   #84
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Default Re: How does 48V 2001 Club Cart OBC function?

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Originally Posted by splee777 View Post
Ok, I'm not sure why this thread went quiet a year ago, but maybe I can get a response from Doc Bob. I appear to have a dead OBC from a 1997 DS. I have a 3rd party automatic charger so it doesn't play a role in the charging, and I've also had to bypass the solenoid lockout as it obviously won't enable it. So, while I don't need the OBC, I would like to repair it if possible. It says 'Fused' on the unit, so maybe it's as simple as a blown internal fuse. Of course, there is the problem of it being fully potted. I was wondering if Doc Bob has done any more investigation, and managed to find the location of the 'fuse' in the unit he tore apart. That way, perhaps I can pry away enough of the potted material to expose the fuse without destroying the rest of the unit.
On the tread going quiet, at least part of that is my fault for not monitoring it. My Club car was running well, other than the batteries were wearing down, as is normal, from running 350 Mi per month. The Villages is a BIG place with many dozens of golf courses, many shopping centers and about 80 places to eat - all accessable by golf cart. So there are plenty of occasions to run the cart. It is saving me about 4000 miles a year on my car.

In the quote, about the "It says 'Fused' on the unit", I am not familiar with that possibility. Perhaps your controller is earlier than the circa 2001 ones I investigated. If it says "Fused", perhaps there is a fuse holder nearby on the controller or maybe one elsewhere in the cart. Club Cars that I have seen are not known for fuses.

The controllers I have seen and the one I did a major disassembly on (destructive unpotting), had no fuses, even beneath the potting. I think they may have just depended on preventing an destructive overload by letting a component burn out, since there was no way to replace something within the potting materal anyway.

In my opinion, repair of a Club OBC is not at all feasible unless it is external to the potting, e.g. a defective external wire or bad connection.
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Unread 05-30-2012, 06:53 PM   #85
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Default Re: How does 48V 2001 Club Cart OBC function?

Yes, my OBC is from a 96/97 cart, and most definitely says 'Fused' on it. See picture below. I have the schematics for my cart and there is no external fuse to the OBC. It gets power directly from the negative B- connection on the controller and the battery side of the solenoid. The reason I suspect a fuse is that there is absolutely no current drain at all from the OBC from these terminals.

Other than the microprocessor burning out, AND assuming you could successfully unpot the board, it would seem that you SHOULD be able to repair the OBC. I paid $150 for my cart and can't see myself spending $200 for a charge controller.

DrBob, if you have any more detailed pictures of the board you deconstructed, could you please post them? Either I'm not privileged enough, or this board doesn't support PMs
Attached Images
File Type: jpg IMG_0454.jpg (203.3 KB, 0 views)
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Unread 05-30-2012, 07:55 PM   #86
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Default Re: How does 48V 2001 Club Cart OBC function?

There should be a fuse on red wire.
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Unread 05-30-2012, 08:38 PM   #87
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Default Re: How does 48V 2001 Club Cart OBC function?

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Originally Posted by Fishing Dude View Post
There should be a fuse on red wire.
Not on my unit. The red wire goes straight to the solenoid battery connection. And no fuse is shown in the wiring schematic either. Maybe they added the external fuse on newer units since THE INTERNAL NON-REPLACEABLE FUSE WAS BLOWING TO MUCH!
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Unread 05-30-2012, 10:04 PM   #88
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Default Re: How does 48V 2001 Club Cart OBC function?

Quote:
Originally Posted by splee777 View Post
Yes, my OBC is from a 96/97 cart, and most definitely says 'Fused' on it. See picture below. I have the schematics for my cart and there is no external fuse to the OBC. It gets power directly from the negative B- connection on the controller and the battery side of the solenoid. The reason I suspect a fuse is that there is absolutely no current drain at all from the OBC from these terminals.

Other than the microprocessor burning out, AND assuming you could successfully unpot the board, it would seem that you SHOULD be able to repair the OBC. I paid $150 for my cart and can't see myself spending $200 for a charge controller.

DrBob, if you have any more detailed pictures of the board you deconstructed, could you please post them? Either I'm not privileged enough, or this board doesn't support PMs
Turns out I disassembled the same revision 1.33 as you have. It also says it is fused, but the schematic I have attached, says the fuse is in the gray (vs red) wire. The fuse may not be what you expect - probably an in-line twist apart fuse.

Also attached are some pictures of the disassembly of the OBC to convince you that it is not repairable. Seperating the epoxy from the electrical compontents would be way too time consuming and risky vs $200 for a new controller.

On a side note, $1000 for a set of T-890s every 2.5 years, with our 4K miles/year usage, has become too much. I am taking delivery of a new Yamaha Electronic Fuel Injection (EFI) cart this weekend. With the trade in of the Club electric, I will have no new information to contribute on OBCs. Of course, for lack of time, I have not published all I know either.
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Unread 05-30-2012, 10:27 PM   #89
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Default Re: How does 48V 2001 Club Cart OBC function?

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Originally Posted by DrBob View Post
...
Also attached are some pictures...
Humm the pictures did not attach to my last message. I will try just the schematic again..

OK, I used the paper clip icon and uploaded the file successfully. Now see if it gets published...
Attached Images
File Type: jpg Club Car 2001 DS Powerglide with MCOR Wiring Diagram.jpg (102.7 KB, 0 views)
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Unread 05-30-2012, 10:31 PM   #90
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Default Re: How does 48V 2001 Club Cart OBC function?

OK that upload worked, I will try the other 4 of the OBC disassembly again.
Attached Images
File Type: jpg IMG_1478(m).jpg (118.3 KB, 0 views)
File Type: jpg IMG_1485 (Medium).jpg (63.7 KB, 0 views)
File Type: jpg IMG_1487 (m).jpg (100.5 KB, 0 views)
File Type: jpg IMG_1494 (Medium).jpg (83.9 KB, 0 views)
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