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Old 04-23-2018, 10:27 AM   #1
sidewalkman
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Default How bad did I screw up?

Hi Guys, first post.
I've got a 2000.5 DS Series. 48V cart. this past weekend I was upgrading the cables to 2G and might have done something pretty boneheaded.
Where the ground passes through the OBC under the seat of course the 2G ground wouldn't pass through....so I drilled it out to fit the new cable. Ran the cable and voila...nothing.
When I first turned it on it surged backwards for 3' then nothing, if I disconnect the battery then reconnect it, same thing, surges either forward or backwards for a couple of seconds then stops. I've ordered a new OBC but I'm wondering what else I could have wrecked...HELP please.

Scott
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Old 04-23-2018, 10:40 AM   #2
Sergio
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Default Re: How bad did I screw up?

You likely only destroyed the OBC, or more precisely the Hal effect sensor around that hole opening inside the OBC.

You can just run the negative small solenoid post (where the yellow wire from the OBC is connected) directly to pack negative or Controller B- if You want to run your cart until the new OBC arrives.

You can use a 5/16" brass stud through the OBC and bolt a cable to each side of the OBC.




ScottyB from cartsunlimited.net also sells the "stud kit" if You prefer to get all the parts that way.
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Old 04-23-2018, 10:46 AM   #3
Raystar57
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Default Re: How bad did I screw up?

The blue ring is the Hal effect sensor.
Never drill it out, use the stud kit as Sergio states.
Carts Unlimited has them.
http://www.cartsunlimited.net/battery-cables.html
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Old 04-23-2018, 11:27 AM   #4
sidewalkman
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Default Re: How bad did I screw up?

You guys are brilliant. The cart is at my rec site, new OBC will arrive Friday, then I'll replace it and let you know. I was worried I might have pooched the Controller, they're expensive.

On that note tho, I likely have a 250 in there, is there any point in upgrading to a 300? All I need is a bit more speed on the hills.
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Old 04-23-2018, 11:31 AM   #5
scottyb
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Default Re: How bad did I screw up?

If the OBC is being used with the factory charger, do not bypass the OBC amperage sensor. Use a stud and 2 cables so the OBC can read the amperage usage.
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Old 04-23-2018, 11:35 AM   #6
NoleFan4Ever
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Default Re: How bad did I screw up?

Quote:
Originally Posted by sidewalkman View Post
On that note tho, I likely have a 250 in there, is there any point in upgrading to a 300? All I need is a bit more speed on the hills.
That is not much, on a series cart you may want to look into an upgraded motor...
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Old 04-23-2018, 11:44 AM   #7
WalterM6
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Default Re: How bad did I screw up?

What about this surging problem? Does the cart take off as soon as you turn the key on or do you have to apply the throttle. Is the solenoid clicking?
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Old 04-23-2018, 11:56 AM   #8
Sergio
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Default Re: How bad did I screw up?

The surging are the capacitors inside the Controller discharging.

The Series drive system is real simple and the Controller has no way of knowing the OBC is not providing the negative to the Solenoid.

When You press the accelerator, the Controller gets the +48v on terminal #1 and activates the output drive, unfortunately the Solenoid did not close so all You get is a "surge" from the capacitors.

You can most likely get another surge if you wait a minute without pressing the pedal so the Controller can charge again through the Solenoid "pre-charge" resistor.
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Old 04-23-2018, 01:06 PM   #9
sidewalkman
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Default Re: How bad did I screw up?

Quote:
Originally Posted by WalterM6 View Post
What about this surging problem? Does the cart take off as soon as you turn the key on or do you have to apply the throttle. Is the solenoid clicking?
have to use the throttle
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Old 04-23-2018, 05:16 PM   #10
WalterM6
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Default Re: How bad did I screw up?

Measure across the two small terminals of the solenoid and see if you got 48V.
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