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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Unread 08-14-2019, 06:36 PM   #1
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Default 2009 RXV: DC Bus High, Software Detected

I've never been able to properly diagnose this one other than 'toss in new controller and hope for the best.

The condition seems impossible given 48V batteries. Code claims the DC volts went like above 72 volts. Book says this issue is uncommon (well, EZGO it's far more common than you'd admit, This makes #3 this year) and what happens is the car locks up and tosses driver off. Typical RXV error behavior. This last one we put a new controller in and it worked out but I despise guessing!

The book says to check all cables, wiring, and power resistor which always checks out. You might drive a minute or days before the issue comes back. Nothing in the handheld live data suggests even the regen could show that high a reading. I can understand DC Bus LOW but not HIGH. HIGH is an impossible condition even if you floored it down a 6% grade with the brake OFF the car.

I finally got an oscilloscope (which saved me already, we had one come in experiencing the symptoms of motor encoder failure which ended up passing thanks to this tool, and was the throttle sensor in the pedal group so it's paid for itself already) so is there a way to use this tool to diagnose this error more accurately or is tossing in new controller the standard operating procedure here?
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Unread 08-14-2019, 10:10 PM   #2
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Default Re: 2009 RXV: DC Bus High, Software Detected

My RXV has 4 X 12V battery setup. I have an Ex-ray Speedometer Kit-ezgo RXV on my RXV. One of the features is to monitor battery pack voltage. It shows real time voltage as you are driving. The top end is 52.6V and then it shows HI. It can handle up to 65V. I watch the voltage go down and up. This is caused by hills, heavy acceleration demands, and regen braking. Regen can send it above the 52.6V and show HI. It never stays HI very long. Maybe a few seconds.

I recommend you find a safe way to monitor the voltage as you test drive. I believe I saw others say the hand held diagnostic tool can do that, but I'm not 100% sure.
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Unread 08-15-2019, 10:43 AM   #3
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Default Re: 2009 RXV: DC Bus High, Software Detected

Quote:
Originally Posted by nickdalzell1 View Post
I've never been able to properly diagnose this one other than 'toss in new controller and hope for the best.

The condition seems impossible given 48V batteries. Code claims the DC volts went like above 72 volts. Book says this issue is uncommon (well, EZGO it's far more common than you'd admit, This makes #3 this year) and what happens is the car locks up and tosses driver off. Typical RXV error behavior. This last one we put a new controller in and it worked out but I despise guessing!

The book says to check all cables, wiring, and power resistor which always checks out. You might drive a minute or days before the issue comes back. Nothing in the handheld live data suggests even the regen could show that high a reading. I can understand DC Bus LOW but not HIGH. HIGH is an impossible condition even if you floored it down a 6% grade with the brake OFF the car.

I finally got an oscilloscope (which saved me already, we had one come in experiencing the symptoms of motor encoder failure which ended up passing thanks to this tool, and was the throttle sensor in the pedal group so it's paid for itself already) so is there a way to use this tool to diagnose this error more accurately or is tossing in new controller the standard operating procedure here?
A controller that has been overvolted can be reset, but it requires a factory or higher level service bench to do that. Overvolts are typically caused by charging a cart to full charge when you live high up on a mountain, then regen down to the bottom to get to a lower elevation golf course. It happens frequently here. I gave E-Z-GO the settings to change on the RXVs to minimixe that from repeatedly occuring and knocking out the controllers. I've reset a few of them for the dealers that must service them.
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Unread 08-15-2019, 03:17 PM   #4
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Default Re: 2009 RXV: DC Bus High, Software Detected

With the handheld it only shows a max of 58V going down a 6% hill and flooring it. I've been unable to force it to go near even 65, much less enough to throw a 72V DC Bus High error. It ended up being the controller but I don't like tossing parts in hoping that's it. Book suggested the wiring harness or encoder could cause that, and I had already ruled out the encoder in this case.
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