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Unread 08-09-2011, 09:59 AM   #11
Gone Wild
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Default Re: Quick OBC bypass question????

Well thats good it may not be the OBC. But will be more trouble shooting. So did the charger kick on when you did the first jumper test inside the charger??
make sure red wire is good from charge receptacle to #1 battery and use an ohm meter on coil of the relay in the charger unplug everything first.
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Unread 08-09-2011, 10:50 AM   #12
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Default Re: Quick OBC bypass question????

What your doing is jumping the grey wire (center wire on receptacle) this is the wire that the OBC uses to turn the charger on and off, by grounding this wire. If manually grounding this wire does not turn the charger on, then the OBC can't do it either. So center lead of receptacle to ground of battery #6.

So all that's left is red wire to receptacle,receptacle, plug, relay in charger
I attached a sheet that shows the charger schematic so you can follow with me easier we are working on the upper 1/3 of the schematic only.
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Unread 08-09-2011, 10:59 AM   #13
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Default Re: Quick OBC bypass question????

As you see on the schematic the DC cord has three wires red,blue,black the red comes from the #1 battery positive terminal so there is 48 volts going to the charger when the DC cord is plugged in. the red goes to the diodes heatsink and then to the charger relay (coil), so the relay has +48 volts when the DC cord is plugged in. Now to make the relay turn on you need a ground source to the other side of the relay (coil), You can see the Blue wire from the DC cord goes to the ground side of the relay (coil) which is the grey wire in the cart, so grounding the grey wire in the cart completes the circuit to the relay (coil), something in this circuit is bad, wire, cord, plug, receptacle, relay,

does this help ??
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Unread 08-09-2011, 11:38 AM   #14
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Default Re: Quick OBC bypass question????

This helps......im going to try to start testing shortly. I appreciatte all the help!

I did the jumper inside the charger and the charger came on and was charging batteries. Does this change anything? This is why I assumed the OBC was bad to begin with.....just from reading other posts.
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Unread 08-09-2011, 11:41 AM   #15
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Default Re: Quick OBC bypass question????

Just so we are on the same page.....my charger is a - PowerDrive 2 - model 22110
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Unread 08-09-2011, 11:51 AM   #16
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Default Re: Quick OBC bypass question????

ThePistonHead,

What was your pack voltage before trying to jump the charger internally?

Did the charger bring your pack voltage up when it was bypassed? Above 36 volts needed to turn the charger on normally?

Attached is a picture of the charge receptacle... do you have continuity with the built in fuse? Do you have continuity with the fuse within the grey wire?

If your batteries charged then the connections from the charger to the receptacle plug are fine. If you have continuity with both fuses then most likely your OBC is bad.
Attached Images
File Type: jpg Charge Receptacle.jpg (180.0 KB, 17 views)
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Unread 08-09-2011, 11:59 AM   #17
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Default Re: Quick OBC bypass question????

Take the upper wires off the relay (coil) in the charger, hook you meter to them, red + and blue -, meter set for higher than 50 volts, with all other wires connected in cart and charger, plug in charger charge receptacle DC, (120 volt plug not plugged in) you should read 48 or so volts.
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Unread 08-09-2011, 12:02 PM   #18
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Default Re: Quick OBC bypass question????

Quote:
Originally Posted by scubabud View Post
ThePistonHead,

What was your pack voltage before trying to jump the charger internally?

Did the charger bring your pack voltage up when it was bypassed? Above 36 volts needed to turn the charger on normally?

Attached is a picture of the charge receptacle... do you have continuity with the built in fuse? Do you have continuity with the fuse within the grey wire?

If your batteries charged then the connections from the charger to the receptacle plug are fine. If you have continuity with both fuses then most likely your OBC is bad.
scubabud this last part how does this check the grey/blue wire going through the receptacle,the grey/blue wires themselves, or the relay.

it does however check the red and black wires if it was actually charging!!.
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Unread 08-09-2011, 12:07 PM   #19
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Default Re: Quick OBC bypass question????

[QUOTE=scubabud;604810]ThePistonHead,

What was your pack voltage before trying to jump the charger internally?

Did the charger bring your pack voltage up when it was bypassed? Above 36 volts needed to turn the charger on normally?

These are great points and would cause the problems you are having check the pack voltage.
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Unread 08-09-2011, 02:15 PM   #20
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Default Re: Quick OBC bypass question????

The pack is reading 47.2V
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