Charging System Troubleshooting

[j_hurst369]

Originally Posted by Sergio

You need both the Grey wire (which activates the charger relay) and the Black wire (which controls the charging current) jumped to pack negative.

If you connect both of those wires to pack negative, it does not matter if the OBC is connected or not, the charger will come ON at full power when You plug it to the cart.

Plug the charger to the cart first and then to the 120v outlet.

Wait until the pack voltage reaches close to 60v and unplug the power cord from the wall first, and then from the cart (to avoid sparks near the cart).

I guess I'm confused... is this the bypass everyone has been talking about? I also ready that the jumper wire should connect from the grey fused wire on the cart side of the fuse to the negative, I did from the receptacle side of the fuse when separated. Didn't know if that mattered?? So you are saying jump a wire from the grey wire to the pack negative, and jump another wire from 1 of the 2 black outs puts on the back of the receptacle to the negative as well?

[j_hurst369]

I'm also thinking I may just buy the new obc today, but there seems to be so many options? How do I know it's it's a power drive or power drive plus, regen, iq, I'm guess I can go based off the serial number but just wanted to verify.

[NoleFan4Ever]

Originally Posted by j_hurst369

I'm also thinking I may just buy the new obc today, but there seems to be so many options? How do I know it's it's a power drive or power drive plus, regen, iq, I'm guess I can go based off the serial number but just wanted to verify.

The serial number for sure. IQ (sepex) carts have the rocker switch for FNR and a pigtail hanging off the motor. Series has the lever arm FNR switch, but look up the serial number to clearly identify.

[Sergio]

Originally Posted by j_hurst369

I guess I'm confused... is this the bypass everyone has been talking about? I also ready that the jumper wire should connect from the grey fused wire on the cart side of the fuse to the negative, I did from the receptacle side of the fuse when separated. Didn't know if that mattered?? So you are saying jump a wire from the grey wire to the pack negative, and jump another wire from 1 of the 2 black outs puts on the back of the receptacle to the negative as well?

Yes, the gray wire will cause the charger to start as soon as You plug it into the the cart without the OBC being involved.

The Black wire (before or after the fuse if the fuse is good) will prevent the OBC from regulating the current as it will by pass it and send the current directly to the batteries.

If the OBC is bad, I would shop for a new "smart" charger instead of replacing the OBC.

Your charger receptacle should look like this:

http://www.buggiesgonewild.com/attac...receptacle.jpg

[j_hurst369]

All the dealers are telling me they can't tell me which one I need without the old ones part number. I don't have the old one though. How do I know if it's a power drive or power drive plus? I don't see a pig tail on motor? Can the dealer not find it by serial number off the cart?

[Sergio]

Of course they can, call David at RevolutionGolfCars.com, a site sponsor, if you want to buy a new OBC.

[j_hurst369]

Originally Posted by Sergio

Yes, the gray wire will cause the charger to start as soon as You plug it into the the cart without the OBC being involved.

The Black wire (before or after the fuse if the fuse is good) will prevent the OBC from regulating the current as it will by pass it and send the current directly to the batteries.

If the OBC is bad, I would shop for a new "smart" charger instead of replacing the OBC.

Your charger receptacle should look like this:

http://www.buggiesgonewild.com/attac...receptacle.jpg

So both those jumpers need to be hooked at the same time?

[Sergio]

Yes, they serve different purposes and both need to be done at the same time.

[j_hurst369]

Originally Posted by Sergio

Yes, they serve different purposes and both need to be done at the same time.

Just an update, I jumped both wires to the negative and the charger kicked on full juice, obc must be bad correct?

[Kashmir]

^sounds like it to me.
Instead of a new OBC, spend just a bit more and get a DPI Accusense charger. Not controlled by OBC and has a float charge that will keep your batteries charged 24/7