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Unread 07-13-2012, 09:04 PM   #1
Not Yet Wild
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Default Powerdrive Charger or OBC Problem?

TIA for any help. I'm sort of "out of my league" with this problem. I've done a lot of searching on the forum but never quite found the same sort of problem.

(My cart is an '86 resistor cart, but I'm "watching" this one for a friend during the summer in AZ.)

1995 Club Car Series cart, 48 volt, Powerdrive charger. S/N is A9507-425058.

I plug in the charger and after about 3-5 seconds, the charger "clicks" and turns on, with the ammeter rising to about 18-19 amps. After about 15-20 seconds, the ammeter drops to zero, and never comes up again.

If I unplug the cart for about 20-30 seconds, the same thing happens.

From the Powerdrive manual I downloaded, apparently the charger is "self-diagnosing" when the meter drops to zero. However, I've not been able to determine how to troubleshoot why it won't restart.

All batteries read the same voltage, approx. 8.17 volts, or approx. 60% charge.

Any help or suggestions about how to troubleshoot would be graciously accepted. I'd like to add that the manual says that after the self-evaluation, the charger will resume, "in a few moments". Maybe I'm not waiting long enough. What is a good description of, "a few moments"? I'm thinking less than a minute. Yes - No?

Thanks for your help,
Chuck
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Unread 07-13-2012, 10:36 PM   #2
Dawg Gone Wild
 
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Default Re: Powerdrive Charger or OBC Problem?

Here's what should happen....

Plug it in

A. 2-10 seconds later it turns on

B. 2-10 seconds later it turns off

C- 2-5 seconds later it turns back on and finishes charging the cart.

When the charger turns OFF in step B, does the relay "click" off? Or does the ammeter simply drop to zero without a relay click?
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Unread 07-13-2012, 10:50 PM   #3
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Default Re: Powerdrive Charger or OBC Problem?

The relay definitely clicks off.
It sounds the same as when it clicks, "On".
(I wasn't sure, so I just went out and tried it again.)
BTW, the Battery light on the dash does nothing - no blinks, no glow, no nothing.

Thanks,
Chuck
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Unread 07-14-2012, 11:21 AM   #4
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Default Re: Powerdrive Charger or OBC Problem?

Quote:
Originally Posted by cdressel View Post
The relay definitely clicks off.
It sounds the same as when it clicks, "On".
(I wasn't sure, so I just went out and tried it again.)
BTW, the Battery light on the dash does nothing - no blinks, no glow, no nothing.

Thanks,
Chuck
Ok, this "Click off" tells you that the cart is commanding the charger relay to turn off, but never back on. The charger is doing exactly as the cart tells it to do. This sounds like an problem with the On-Board computer. But first lets eliminate the obvious. Replace the 3/8Amp fuse in the small yellow fuse holder behind the receptacle. I've seen them develop internal shorts before and work for a little while and then stop working. Also, have you changed any of the wiring configuration on this cart? This is the same symptom that develops a lot of times when people upgrade their wires to a larger size but don't bother to insert the main negative cable "Through" the OBC, instead they go around it. There is a sensor inside the OBC that monitors voltage through that wire, and it must be in place for it to work properly. With these two things in mind, replace the fuse and check the wiring. If it still does the same thing, replace the OBC. On a 1995 series cart the OBC is part number 101800606.

EDIT: You may also want to give a slight tug to the grey wire in the back of the charger receptacle to make sure there's not an internal short in the receptacle itself. I've seen this before as well.
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Unread 07-14-2012, 11:48 AM   #5
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Default Re: Powerdrive Charger or OBC Problem?

David,
I appreciate your help.

This isn't my cart and I didn't change any of the wiring. Everything looks original to me, except that the batteries have been replaced. I did look to make sure the negative lead was run through the OBC.

I'll check/replace the fuse and double-check the wiring in the charger receptacle.

If all that checks out OK, you stated that the OBC is bad. Right? An OBC reset wouldn't do anything, huh?

Thanks for your help.

Chuck
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Unread 07-14-2012, 01:19 PM   #6
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Default Re: Powerdrive Charger or OBC Problem?

Hi again,

I checked the fuse behind the receptacle but didn't have a replacement. Taking out the fuse, I jumpered the wires together to see if it would make any difference. It didn't, so I put the fuse back in.

I checked the wire(s) in the receptacle and all looked good.

Following the instructions I found in the stickies, I reset the OBC.

SUCCESS!

The charger now operates properly, with the needle dropping to zero for self-evaluation but without the "click". Within a few seconds, the charger ammeter shows current being supplied to the pack.

I'll keep an eye on it for a while and make sure it doesn't get all messed up, somehow. If it goes wacky again, I guess I'll have to replace the OBC. But right now, all is well.

Thanks,

Chuck
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Unread 07-15-2012, 05:49 PM   #7
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Default Re: Powerdrive Charger or OBC Problem?

Quote:
Originally Posted by cdressel View Post
Hi again,

I checked the fuse behind the receptacle but didn't have a replacement. Taking out the fuse, I jumpered the wires together to see if it would make any difference. It didn't, so I put the fuse back in.

I checked the wire(s) in the receptacle and all looked good.

Following the instructions I found in the stickies, I reset the OBC.

SUCCESS!

The charger now operates properly, with the needle dropping to zero for self-evaluation but without the "click". Within a few seconds, the charger ammeter shows current being supplied to the pack.

I'll keep an eye on it for a while and make sure it doesn't get all messed up, somehow. If it goes wacky again, I guess I'll have to replace the OBC. But right now, all is well.

Thanks,

Chuck
keep an eye on it as in most cases OBC reset when it works is temporary and chances are its going to act up again..............................
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Unread 07-15-2012, 10:52 PM   #8
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Default Re: Powerdrive Charger or OBC Problem?

Quote:
Originally Posted by shadowman View Post
keep an eye on it as in most cases OBC reset when it works is temporary and chances are its going to act up again..............................
Exactly.... This may be temporary so keep an eye on it.
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Unread 07-16-2012, 02:33 PM   #9
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Default Re: Powerdrive Charger or OBC Problem?

Comments understood perfectly.
Thanks for all the help.

Chuck
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