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Unread 04-29-2013, 08:01 AM   #1
Not Yet Wild
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Default Earth wire through OBC

I just put new heavier wires throughout my buggy and was wondering does the earth wire need to go back through the OBC. Ever since I changed them I seem to have problems charging.I didn't go through OBC because it didn't fit. Cart is a 2003 48v IQ .
Thanks Phillip.
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Unread 04-29-2013, 08:12 AM   #2
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Default Re: Earth wire through OBC

Yes, the earth (ground) wire needs to go through the OBC for proper charging,
Some people have run an additional ground wire through the OBC with the larger cable going around it,
but, in some instances, the battery pack wouldn't get a full charge.
Scottyb (Carts Unlimited ~ BGW sponsor) has an OBC kit that eliminates the separate wire.
I'm not sure if he ships to Australia, that's something you'd have to ask him!

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Unread 04-29-2013, 09:00 AM   #3
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Default Re: Earth wire through OBC

Make your own.

Take a 3" length of 5/16 threaded stainless steel. Wrap a 1/2" thick piece of insulator tape in the center. Stack yourself 2 x 1 1/2" neoprene 5/16 washers, 2 x 1" 5/16 plastic washers. One on each side of the tape gap. Then stainless washer and nut on either side to snug the shaft up in the hole. Then the stainless washers and nuts to make battery posts on either side after the first set of washers and nuts. 3" works depending on the thickness of your washers.

Be careful not to overtighten the nuts after placing stack through the hole and you obviously have to hold the first set of nuts with a wrench when tightening the final nuts. Now you essentially have battery posts on either side of the OBC and you can do whatever thickness of cable you want. It looks like CC made it that way. I used 4 gage. Coat everything in dielectric grease.
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Unread 04-29-2013, 09:15 AM   #4
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Default Re: Earth wire through OBC

I left the original wire in and the 2g going around like Lockman said, it is working fine as far as I can tell. Does anyone know exactly what the OBC is reading? Is it just reading pack voltage?
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Unread 04-29-2013, 09:25 AM   #5
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Default Re: Earth wire through OBC

Don't quote me SC, but I'm pretty sure the OBC senses charging and discharging amperage,
It's to my understanding with some that were having problems with the double cable type setup,
the 6g doesn't let the OBC properly sense the actual charge/discharge of the pack.
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Unread 04-29-2013, 09:30 AM   #6
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Default Re: Earth wire through OBC

This is how I did mine.
Cable upgrade with OBC
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Unread 04-29-2013, 09:38 AM   #7
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Default Re: Earth wire through OBC

Well I would have to agree that my way is certainly the easiest but not the best way for sure.
What I dont understand is why it matters so much if the obc is till taking the chare up to 65 volts prior to shut off, wouldn't that indicate it was fully charging?
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Unread 04-29-2013, 09:42 AM   #8
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Default Re: Earth wire through OBC

Quote:
Originally Posted by Speedchaser View Post
Well I would have to agree that my way is certainly the easiest but not the best way for sure.
What I dont understand is why it matters so much if the obc is till taking the chare up to 65 volts prior to shut off, wouldn't that indicate it was fully charging?
I don't think it does matter if the charger is shutting off. The only reason I use the stud is because I read where some people "heard" of problems with the 2 cable method. Probably nothing to it. I was also cramped for space with the 2ga cable and the conversion.
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Unread 04-29-2013, 09:42 AM   #9
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Default Re: Earth wire through OBC

I was able to soap up the replacement 2AWG cable and get it through the hole in the OBC.
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Unread 04-29-2013, 09:44 AM   #10
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Default Re: Earth wire through OBC

Quote:
Originally Posted by jfcody3962 View Post
I was able to soap up the replacement 2AWG cable and get it through the hole in the OBC.
I think it depends on the type and or brand of cable. I tried the lubrication method and it wasn't even close to fitting through the hole.
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