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Old 01-21-2016, 07:01 AM   #1
Sergio
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Default OBC Bypassing

I think the White and Blue work better for all years IQ and Excel carts.

For the Regen-2 and other Model Years where the Blue wire was connected to the harness instead of the controller, the OBC provided power directly to the electrical system.
If the White and the Red/White wires going to the OBC are the same gauge, I would still use the White wire, but add a 10 amp inline fuse.

If the Red/White wire is a larger gauge, then use the Red/White on the OBC side of the connector and keep the fuse.

I like the idea of not having any power going to the Controller connector when the Tow/Run is on Tow (which is how the OBC works).

Using the Red wire would also provide non-fused 48v power at the controller connector.


The above information is for Sepex only systems.


All model years of the Series carts, the OBC provided the negative side of the Solenoid on the Yellow wire.

For the Series carts You just have to disconnect the Yellow wire from the OBC and run it directly from Solenoid to controller B- (or other negative source like pack negative).
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Old 01-21-2016, 06:17 PM   #2
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Default re: OBC Bypass ~ Technnical Tips

I'll add a little tip for those people who want to make this modification. I've often been asked what procedure is best used to make this modification. The OBC that is being bypassed has usually failed, creating the need to bypass it and use a standalone charger. Before you throw it in the trash, cut the 6 pin plug off of the old OBC, disassemble it and remove all of the unnecessary wires (Everything except the white and blue wires). Make a connection between the white and blue wires of the 6 pin plug. Butt connectors will work, but I prefer solder and heat shrink tubing. Plug the 6 pin connector back into the wire harness.
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Old 01-21-2016, 08:40 PM   #3
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Default re: OBC Bypass ~ Technnical Tips

I did not know this was going to be a sticky, so let me add a little more detail.

You also need to by-pass the OBC charging current control SCR by running the negative 10ga wire from the back of the charger receptacle directly to B- or pack negative.

The fuse is only needed on the Older Regen carts.

The IQ and Excel carts already have a fuse on the white wire before the Tow/Run switch.


I took a few pictures to illustrate David's comments about removing the unused pins from the 6-pin OBC connector.

Picture 1:
This is the Tab that locks the pins in place inside the OBC 6-pin connector, note the opening on the side of the Tab.
Picture 2:
To remove the Tab use a "pick" or a small screwdriver to slide under the opening and pull the Tab OFF the connector.
Picture 3:
Use a small screwdriver to move the individual pin locking tab to the side and pull the wire from the back to remove the pin OFF the connector.

Attached Images
File Type: jpg OBC_6pin_2.jpg (142.8 KB, 0 views)
File Type: jpg OBC_6pin_1.jpg (81.2 KB, 0 views)
File Type: jpg OBC_6pin_3.jpg (178.0 KB, 0 views)
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Old 01-21-2016, 09:44 PM   #4
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Default re: OBC Bypass ~ Technnical Tips

Quote:
Originally Posted by Sergio View Post
I did not know this was going to be a sticky...
Yeah, well... Scotty felt it was pertinent information, and I felt that the info you provide to BGW is well worth the sticky!

Carry on!

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Old 08-19-2018, 08:40 PM   #5
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Default re: OBC Bypass ~ Technnical Tips

Forgive me, as I am still working my way through all 19 pages, but I want to get it clear in my mind, and this process helps.

The cart has a DPI DPL charger. Will that still be a good charger without the OBC? Maybe I will have to research that also.


Quote:
Originally Posted by Sergio View Post
The IQ and Excel carts already have a fuse on the white wire before the Tow/Run switch.
Small issue, but my cart is a 2011 I2 Excell, and there is only a fuse AFTER the run/tow switch.

The white wire gets the power after both the run/tow switch and the 15A fuse. Jump that white wire to the blue wire which gives the controller the signal to operate whenever the run/tow switch is in the run position.

The red wire at the OBC is unfused and hot regardless of the position of the run/tow switch.

The yellow wire gets power when the throttle pedal is depressed. However, the controller has to supply the voltage to the throttle switch(along with the key switch) initially.

I believe the brown/white wire supplies a ground for the dash light. Causing it to illuminate. (Hot for the light is supplied from the key switch).

I understand the black 10ga wire from the charge port goes to the battery -, but what of the smaller grey wire? Connect it to battery pack negative also? (Depends on charger?)


Also, My OBC controller has an additional black ground wire that connects to the controller B-, but is not shown on my print.
What's up with that?




Quote:
Originally Posted by Sergio View Post
If You don't connected the White and the Blue wires together, You may experience the OBC going to sleep.
[/B]
You mean the controller will go to sleep? The OBC will be bypassed and it's condition is not relevant, right?


Quote:
Originally Posted by TahoeDawgZ71 View Post
The OBC is great for dealers. For an individual owner, it's worthless. It logs charge data and battery information that the dealer can retrieve with a Communication Display Module (CDM). There is an infrared sensor in the little orange battery light on the dash. Hold the CDM close to the sensor and it will tell you why the last charge cycle terminated.
Um...what?
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Old 08-20-2018, 06:16 AM   #6
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Default re: OBC Bypass ~ Technnical Tips

The point on that fuse comment is that the OBC white wire is fused and controlled by the Tow/Run switch, so it is the best wire to provide the by-pass lockout signal to the Controller.

The gray "sense" wire should be left disconnected for safety.

If You do connect the gray wire to the pack negative, the old style Power Drive or the DPI BTL charger will run uncontrolled as long as they are plugged to the cart.

The other 10ga black wire "combo crimped" at the Controller B- is to provide a negative to any accessories You wire.

That is only important if You are using the OBC for charging as the system requires the OBC to measure all current going in and out of the batteries.

If a working OBC does not sense the charger plugged to the cart it will put the controller to sleep after 3 days. This is irrelevant if the OBC lockout signal is by-passed.

The dash light has both a visible light to indicate charging problems as well as an infrared light that transmits charging data.

Here is a trick for checking TV/etc infrared remotes or if You want to see that dash light infrared light operate, just use you phone's camera as it picks up infrared really well.

If You point your phone's camera to the dash light in a darker environment, You will see the infrared LED blinking from the right side of the dash light.
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Old 01-25-2016, 01:26 PM   #7
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Default re: OBC Bypass ~ Technnical Tips

The sticky may simplify the process when you get a 100 post from 100 different users wanting the same information. It is a handy tool commonly used in many forums for the same reasoning.
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Old 02-29-2016, 11:27 AM   #8
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Default re: OBC Bypass ~ Technnical Tips

Should we change the title to "Bypassing Club Car IQ/Excel OBC"?
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Old 02-29-2016, 02:07 PM   #9
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Default re: OBC Bypass ~ Technnical Tips

Quote:
Originally Posted by jakesnake27 View Post
Should we change the title to "Bypassing Club Car IQ/Excel OBC"?
It would definitely apply, the procedure is the same.
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Old 03-01-2016, 08:33 AM   #10
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Default re: OBC Bypass ~ Technnical Tips

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