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Unread 09-09-2014, 04:29 PM   #11
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Default Re: My 2001 DS won't stop charging

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Originally Posted by Golfdog View Post
I would now suspect the OBC is faulty as it should have shut off the charger after 16hrs. If you can get access to another cart with a known good OBC, plug in your charger and see if it switches the charger off.
Thanks, Golfdog. I shall take the charger in to my nearest Club Car service agent and get them to check it out. It's probably worth whatever it would cost in order to eliminate one of the possible causes of my problem.
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Unread 09-09-2014, 05:55 PM   #12
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Default Re: My 2001 DS won't stop charging

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Okay, Sergio, I have the following on-charge readings from my multimeter:

Total pack 64.4 volts
Battery 1 (+) 10.53 volts
Battery 2 10.90 volts
Battery 3 10.67 volts
Battery 4 10.67 volts
Battery 5 10.95 volts
Battery 6 (-) 10.59 volts

The individual battery voltages only add up to 64.31 volts, so I seem to have lost 0.09 volts somewhere along the way! Do you see anything significant in these figures?

I have unplugged the charger as I don't want to risk leaving it on overnight. I shall check the off-charge voltages tomorrow morning, 15 hours after ending the charge.
The 20v scale on the meter is more accurate than the 200v You used to measure the pack voltage, that is the difference.

Battery #1 and #6 should have been higher, but they are all above 10v, so that is good.

I assume that when you plug the charger on AC only, that there is no hum from the charger. When you then plug the DC cord into the cart, the charger should click On-Off-On before the bulk charge (12amps) starts.

If that is case, it does sound like the OBC, but like GolfDog mentioned, if you can get either a good charger to test on your cart or test your charger or a good cart, that would be better.

Also, to reset the OBC, just leave the battery disconnected for 20 minutes. The part about the buzzer sounding is only for older carts where the buzzer was powered by the battery and not by the controller.
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Unread 09-09-2014, 07:25 PM   #13
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Default Re: My 2001 DS won't stop charging

Thanks, Sergio. The information about resetting the OBC was particularly useful. I'll certainly give that a try. I have been puzzling for ages about the lack of buzzer noise; someone ought to add the fact that later models don't buzz to the OBC reset Sticky thread if they have not done so already. Perhaps I missed it as I just read the first post of instructions.

The general consensus amongst you guys with knowledge and experience on my thread and on fngcarter's similar thread seems to be pointing towards the OBC being at the root of my problems. I now have to decide whether or not to take the $300 (in the UK) gamble of buying a new OBC. I shall get the charger checked out first, I think.
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Unread 09-10-2014, 07:17 AM   #14
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Default Re: My 2001 DS won't stop charging

15 hours after switching off the charger last night (total pack on-charge voltage 64.31 volts), the total pack voltage is now 50.75 volts, with all six batteries in the range 8.44 volts to 8.48 volts.

Oddly, batteries #1 and #6, which had the lowest on-charge voltage, now have the highest voltage, both at 8.48 volts.
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Unread 09-11-2014, 06:17 PM   #15
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Default Re: My 2001 DS won't stop charging

I played 18 holes today and checked the state of charge of the batteries one hour after completing the round. Amazingly, the total pack voltage was 50.0 volts, just 0.75 volts down on when I started the round. All six batteries were in the range 8.30 to 8.35 volts, so I reckon there's not a lot wrong with the batteries.
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Unread 09-13-2014, 03:55 PM   #16
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Default Re: My 2001 DS won't stop charging

Eureka!!!!!!

I put the DS on charge after my round and decided to check it every 30 minutes or so. It started charging at 15 amps, dropped gradually down to 4 amps then, after about 2 hours charging, on came the orange light on the dashboard. I switched off the charger at the wall socket, pulled the 3-pin charger connector out from the cart and then plugged everything back in and switched on the charger again. After 15 minutes, the orange light was back on, so I disconnected everything again and plugged it all back in again. This time, however, the orange light stayed off, and stayed off, and stayed off for about five hours, at which point, just after I had checked the battery voltages (total 64.2 volts), there was a click and the charger switched itself off, just like it should.

The charger is still plugged in and switched on at the wall socket and is still on zero charge as it should be.

I am now hoping that I have jolted the OBC back into shape permanently.

Fingers very firmly crossed!!!!!!
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Unread 09-13-2014, 05:09 PM   #17
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Default Re: My 2001 DS won't stop charging

I think I need to check my battery light because it never comes on. Do you know how much voltage makes the light turn on? I will follow your exact steps of plugging and unplugging and switching on and off lol. Maybe this is a different way of resetting the obc charging circuit. Thanks for informing me.
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Unread 09-13-2014, 05:29 PM   #18
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Default Re: My 2001 DS won't stop charging

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Originally Posted by fngcarter View Post
I think I need to check my battery light because it never comes on. Do you know how much voltage makes the light turn on? I will follow your exact steps of plugging and unplugging and switching on and off lol. Maybe this is a different way of resetting the obc charging circuit. Thanks for informing me.
In theory, the orange warning light on the dash should not come on if all is well, as it is meant to tell you that something is not right. However, my charger manual tells me that it should come on for 10 seconds if the charge is discontinued with batteries less than 90% charged. So if you take your buggy out for a round of golf, then put it on charge for, say, 30 minutes and then switch off the charger and pull the charger cord plug out of the socket on the buggy, the orange light should come on for 10 seconds.
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Unread 09-13-2014, 07:19 PM   #19
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Default Re: My 2001 DS won't stop charging

Peter, are you saying you think the charge plug was not getting a good connection and by plugging and unplugging you caused the connection to connect better?
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Unread 09-13-2014, 11:13 PM   #20
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Default Re: My 2001 DS won't stop charging

Well Peter I tried what you did and so far nothing different. Only time will tell
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