Charging Problem after 6X8 conversion

bajarebel1

I just finished converting my 2004 CC Precedent fron 4X12 to 6X8 as shown in the stickies. I installed brand new Trojan T-875 batteries and upgraded all cables to 2AWG welding cable. I plugged in the powerdrive charger and it will not come on and the battery light on the dash comes on solid then starts blinking. I did an OBC reset but never got any buzzer sound. I bypassed the obc in the charger and it turns on to 15amp. my pack voltage is reading 50.6 and i also checked voltage in the charge receptacle on the cart 49.4 grey wire to red wire and 40.2 red wire to black wire. the OBC part # in the cart is 26445.03. I have no idea why it will not charge can someone please help and point me in the right direction. sorry for the long post just tried to supply as much info as possible.

BGW

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89GatorClub

Are you saying when you took your reading when charging the charger is only putting out 49.4 volts?

bajarebel1

no that reading was just off the charge receptacle on the cart with no charger connected. the only time i got charger to come on was when i bypassed obc in the charger with the jumper and it showed 15amp on the charger but i did not leave run long enough to take a voltage reading because i was afraid i would damage my new batteries

89GatorClub

At 15 amps you won't hurt the new batteries unless they are wired up wrong. Mine always starts out from 15-20 amps whenI first plug it in. The amps will drop as the batteries take a charge

bajarebel1

I did not think it would drop off with the obc bypassed in the charger. I followed direction on another post and this it what it said.

CAUTION: this bypasses the OBC and charger will not automatically shutoff . . . monitor the charger and only bypass long enough to bring pack voltage above 38v.

89GatorClub

Correct what I was geting at is you have plenty of time to take voltage readings. Assuming you don't take a few hours to take the readings

Speedchaser

OK, if you upgraded cables to 2g you probably did not take the main negative from the battery pack through the OBC hole. If that cable does not go through the OBC hole it will not turn on the charger.

I put in 2g cables also but left the original 6g main that goes through the obc hooked up and the 2g cable is also hooked up but does not go through the obc hole. Everything is working fine so far. But that wire has to go through the OBC, unless you eliminate the obc and go to a DPI charger.

CRK

*TAKE THIS WITH A GRAIN OF SALT* This is my experience only and is not meant to be the rule.


The charger will charge and the meter will go down, the problem is the obc is out of the loop now and will not tell the charger to turn off after a full charge.

With this in mind and if you are wanting to charge the batteries, you have to monitor the charger and the pack voltage the whole time.

The charger will start off high 15-20amps then it will gradually fall as the batteries take the charge. The pack voltage will go up as high as around 63 volts.

Now then, I dont know what max voltage is safe, but I have never let mine go above 63 volts when bypassing the OBC and doing the relay bypass on the charger.

I dont know if the batteries got the full multi stage charge they are supposed to get when doing the OBC by-pass.

Also I have never done this to a new set of batteries, only my very tired 3 + year old set.

bajarebel1

I was able to get the cable thru the obc it was not easy but the negatve cable is routed thru the hole in the obc

bajarebel1

this is good to know that i can charge with it bypassed but i am still wanting it to be fixed so that it is right.