How-To OBC Bypass the Easy Way

[movin-on]

Brown goes to the warning light on the dash...

[Mfrancis]

Thanks I greatly appreciate that, I wanted to make sure I understood exactly what was what before I cut any wires.

[Bourbon60]

Originally Posted by Fairtax4me

I don't think this one needs to be locked, at least not right away.
If someone still has questions pertaining to the original topic of the thread, or has info that may help clarify or improve the original post then I'm more than happy to try to answer those questions and get info changed or added to the post.

So the black wires that you are connecting - is it tying three wires in the yellow butt connector? Or is one black wire left cut and not connected to anything?

[scottyb]

Originally Posted by billythekid13

I'm going for the redneck yard of the week.

You're going to need a hole lot more than a broken golf cart to win this category

[Fairtax4me]

Originally Posted by Bourbon60

So the black wires that you are connecting - is it tying three wires in the yellow butt connector? Or is one black wire left cut and not connected to anything?

Only two black wires are connected. The black wire in the harness that comes from the Charge Receptacle should connect to the short black wire that goes to B- terminal of the controller.

[Theflyinglineman]

Originally Posted by Fairtax4me

There's a thread about this already, but it's multiple pages long and covers a bunch of different stuff. Some of which doesn't really apply to the bypass, some does, but most of it is spread out and difficult and confusing to find exactly what you need.

So here is a quick and easy way to properly bypass the OBC on your Club Car cart.
This applies to MOST 48v Electric Club Car carts equipped with an OBC. Some earlier models may have minor differences, but the process will be much the same for all OBC equipped carts.
I don't want to get into the "Why" to bypass the OBC in this thread. I'm just going to cover the "How" with hopes that it helps people more easily find and make the proper connections to bypass the OBC.

This should cover Club Car DS and Precedent, as well as other sub models based on the DS platform such as Villager, Carryall, Turf, and many other 48V electric Club Car models.
These photos show the proper connections to be made for a SEPEX drive system. SERIES carts will vary just slightly and I will cover those a bit later.


The basics are that we need to bypass the charge current (amps) regulating circuit of the OBC which is done on the Black negative wires. We need to connect the Charge Receptacle Negative to the Pack Negative which can easily be done right next to the OBC without needing to use any new wiring, or re-route any wiring. This has to be done for a new "smart" charger to work properly.
We also need to bypass the OBC lockout function of the controller. We provide 48V to the controller on the lockout wire so the controller will allow the cart to operate. Normally the OBC provides this voltage, but if the OBC has failed it may not provide that voltage any longer, and the controller will not allow the cart to operate. This is how the OBC puts the controller in Charge Interlock or Lockout to prevent motion of the cart while the charger is plugged in. So to get around this, we will take the 48v input from the Tow/Run switch that goes to the OBC on the White wire, and jumper that voltage to the Blue wire that inputs the controller interlock. Supplying 48v to the controller on the Blue wire Disables the interlock and allows the cart to operate.


Very simple, all you need is two crimp connectors. 1 Yellow and 1 Blue.
Before starting any electrical work on the cart, ALWAYS flip the Tow/Run switch to TOW, and Disconnect the Battery Pack Main Negative Cable!

Find the Two Black wires going into the OBC, and find the White and Blue wires in the OBC 6 pin harness connector.


Cut the Black wires a few inches from the OBC, strip the ends about 3/8", and join them together with the Yellow crimp connector. This completes the circuit from the Charge Receptacle - to the B- connection at the controller, or at the terminal block next to the controller on some carts. Either way, this provides a direct path to the Battery Pack Main Negative.

For the White and Blue wires we can do this several ways. In this example I have just cut the wires on the CART side of the connector and joined them together with a blue crimp connector. That's all that is Necessary to complete the bypass, and now you can use any Smart charger you like to charge your pack, and the cart will operate with no inhibition.



You can also clip the wires on the OBC side of the connector, leaving several inches of wire coming out of the connector. Join the two together in whichever manner you prefer (solder and heat shrink, crimp connector, etc).
Then clip off the other wires at the base of the connector, or disassemble the connector and remove the other wires and their pins from the connector entirely.
Some people prefer to remove the OBC entirely at this point. I'll leave that up to you.

The cart in these pictures is an older Regen 2 cart, and while the wire coloring is similar, you will find that on Precedent and DS IQ or Excel carts you will have a Light Blue wire, rather than Dark Blue. In those carts the Light Blue is the lockout wire, and needs to be connected to the White wire.


On a Series cart, you will not have a 6 pin connector as pictured. You will have a 3 pin triangular connector with a Red, Brown, and Yellow wire.
The Yellow wire is the Negative for your solenoid and is how the OBC handles charge lockout on a Series cart. Clip the Yellow wire on the Cart side of the connector, and join that Yellow wire with your two Black wires in the same crimp connector to provide the negative connection for your solenoid to operate.
Or crimp a 5/16" ring terminal connector on the Cart end of the yellow wire, and attach it to the B- terminal on the controller, or B- terminal block near the controller if your cart has one. At this point your Series cart OBC is bypassed, and can be removed from the cart if you prefer.

As for the Grey wire from the charge receptacle. It's not Necessary to do anything with the Grey wire. If you plan to remove the OBC, unplug or cut the grey wire at the OBC end, and tape/zip tie it out of the way. It can be used for lockout function with certain chargers.

Some people prefer to have, or need to have a lockout function for the Charger, which can also be easily done, but how to do that will vary based on which cart you have, and which charger you have. I'm not covering that info in this thread as it is a wider topic. If you have questions about the setting up a charger lockout there are several other threads here on the forum which cover that well, and if none of those are helpful please start a new thread asking any questions about your specific needs.

If anyone has info I may have missed, or that needs clarification or correction, please let me know and I will try to update this thread. I've tried to make this almost self explanatory, but sometimes what is obvious to one person may not be so obvious to others.

On a series cart what is the function of the red wire and what do you do with it when removing the obc
Thanks
Adam

[Fairtax4me]

Originally Posted by Theflyinglineman

On a series cart what is the function of the red wire and what do you do with it when removing the obc
Thanks
Adam

Small red wire going to the OBC is 48v power going in for the OBC to operate. Should come from the solenoid, and can either be cut and taped off, or totally removed when the OBC is gone.

[Theflyinglineman]

Originally Posted by Fairtax4me

Small red wire going to the OBC is 48v power going in for the OBC to operate. Should come from the solenoid, and can either be cut and taped off, or totally removed when the OBC is gone.

Thanks

[DGNdennis]

I'm new to this. Have a club cart trying to bypass. Followed the thread, but new smart charger only shows power on. Do the batteries still have to have at least 36v to charge. Thanks for any advise. Dennis

[Fairtax4me]

There is a minimum voltage for most smart chargers to recognize the pack or they will not charge.

What is the voltage at the Red and Black wire pins on the charge receptacle? It should be the same as pack voltage if you did the bypass correctly.