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Unread 11-08-2010, 12:48 AM   #31
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Default Re: Melted batt. terminal

doh! this thread jumped ahead like 8 posts while i was reading about nuts & bolts
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Unread 11-08-2010, 01:31 AM   #32
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Default Re: Melted batt. terminal

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Originally Posted by scottyb View Post
The question here is whether the OBC sees full voltage through the bypass. My understanding of electrical conductors tells me it does see the same voltage as the main cable. I think it does not see the same amperage but, I think it sees the same voltage. (I think the OBC is looking for specific voltage) This is something worth trying if you think you have a problem in this area. I would tend to use a fat plastic standoff type washer (1/4") on the metal side... I would like to know what you think of this once you get it going.
heres what i suspect is happening:

the obc uses a hall effect sensor to measure current. (think clamp meter) 2 parallel cables result in each cable carrying 1/2 of the current. so, 1/2 gets measured by the obc sensor, the other 1/2 bypasses the sensor. since the current consumption vs voltage readings don't match that of a good battery pack, the computer thinks "****, these batteries suck. i need to condition the pack." and schedules a conditioning phase at the end of charge sequence. (boiling)

scaling the sensor readings x2 would fix this. (basically, a single line of code in the software) this is not a option unless the programming pins on the computer are broken out on the harness.
-sj
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Unread 11-08-2010, 07:39 AM   #33
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Default Re: Melted batt. terminal

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Originally Posted by sonicj View Post

scaling the sensor readings x2 would fix this. (basically, a single line of code in the software) this is not a option unless the programming pins on the computer are broken out on the harness.
-sj
SJ scaling x2 would not work unless both cables were identical electrically in all ways (length,diameter.resistance,ect) not to mention terminal connections.
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Unread 11-08-2010, 08:15 AM   #34
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Default Re: Melted batt. terminal

correct. i didn't get that far into it since its basically a hypothetical pipe dream, but if it were possible, you would scale to the correct resistance ratio for your cables.
-sj
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Unread 11-08-2010, 08:28 AM   #35
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Default Re: Melted batt. terminal

[QUOTE=sonicj;477253]heres what i suspect is happening:

the obc uses a hall effect sensor to measure current. (think clamp meter) 2 parallel cables result in each cable carrying 1/2 of the current. so, 1/2 gets measured by the obc sensor, the other 1/2 bypasses the sensor. since the current consumption vs voltage readings don't match that of a good battery pack, the computer thinks "****, these batteries suck. i need to condition the pack." and schedules a conditioning phase at the end of charge sequence. (boiling)

scaling the sensor readings x2 would fix this. (basically, a single line of code in the software) this is not a option unless the programming pins on the computer are broken out on the harness.
-sj[/QUOTE

I'm thinking you guys are onto something here, it would make sense in my case. You lost me on the scaling, I a dumb novice, however I agree the obc is not giving the charger accurate info, so they keep charging. Also, it's as if my batts. never conditioned initally. I tried "breaking" them in based on the info. from this forum and I never got any volt changes from before to after. The batts. are two years old(Energizer, Sam's batts.) so they may not be worth a darn....another theory? Anyway, for now all I could find was a zinc threaded rod. I will try to secure stainless or see what an electrical shop recommends and let you guys know what happens. Thanks for all the input.
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Unread 11-08-2010, 11:29 PM   #36
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Default Re: Melted batt. terminal

Another thought......

Bypass the OBC completely and install a 48 volt timer in the charger itself.......

something along the lines of this timer usually works for me......

http://www.nivelparts.com/pages/product.aspx?sku=3541
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Unread 11-09-2010, 09:42 PM   #37
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Default Re: Melted batt. terminal

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Another thought......

Bypass the OBC completely and install a 48 volt timer in the charger itself.......

something along the lines of this timer usually works for me......

http://www.nivelparts.com/pages/product.aspx?sku=3541
So, your are saying basically force charge it. Disconnect the relay or jumper in the charger and force charge it! I've done this before when my precedent's obc went bad. Is the only funcion of the obc to regulate charging.....because that would be easy...just a little more maintenance. However, I did find 36", 3/8 brass threaded rod today. I'm going to cut it down to 3"...should be enough room for: 4x 3/8 nuts, lock washer, and plastic washer on the metal side of the obc. I wil have to monitor heat and corrosion around this connection on the obc. BTW, stainless is not recommended because most grades of stainless are only electroplated and will corrode as fast as anything else. So, I'm told by the local electrical supply house. I'll let everyone know how it goes,....I have plenty of brass to play with.... Now, should I use brass nuts? I think I'll use stainless on the washers and nuts and just monitor them. It shouldn't arc with so little steel.
Thanks all for the inpjut.
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Unread 11-09-2010, 09:46 PM   #38
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Default Re: Melted batt. terminal

David may have a fit
I would just sell the charger & toss the OBC.
Then get a standalone charger and be done with this reoccurring problem
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Unread 11-09-2010, 10:28 PM   #39
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Default Re: Melted batt. terminal

I would never suggest force charging it. The net effect of adding the "timer" is the same as using a stand alone charger. It is a "smart' timer that constantly monitors voltage within the pack and adjusts amperage as needed.

On the 95, the OBC should only be responsible for charger monitoring. I know on the newer carts, the OBC is more tied into the rest of the system, but I believe the 95 was still a basic function year.
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Unread 11-12-2010, 07:58 PM   #40
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Default Re: Melted batt. terminal

Well, I found some 3/8" threaded brass, I'll work on this weeked and take some pics. I've cut 5x 3" 3/8 rods...that should be plenty for washers, nut, and jam nut. I had to buy 3' of it @$12 per foot....I have some extras.
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