1999 48v CC DS regen2 not charging

Bloup101 · 08-13-2019, 08:36 PM

@fairtax4me, it would help if I gave proper measurements, I mesured again.
Battery pack 49.94v
Battery pack positive, charger receptacle negative 37.33v
Charger receptacle + and - 37.33v
So I do have more than 10v difference.
Now what?

@walterm6, the black wire from the charger receptacle is hard wired to the OBC and I verified continuity successfully from the charger receptacle to the back of the OBC using a needle. Should I get continuity to the nut labled NEGATIVE BATTERY VOLTAGE at the back of the OBC?

Tks for your help

WalterM6 · 08-13-2019, 08:59 PM

Bloup101 It looks like it's wired ok but the green wire hanging out and not connected looks suspicious.

Fairtax4me · 08-13-2019, 09:45 PM

Quote:

Originally Posted by Bloup101

@fairtax4me, it would help if I gave proper measurements, I mesured again.
Battery pack 49.94v
Battery pack positive, charger receptacle negative 37.33v
Charger receptacle + and - 37.33v
So I do have more than 10v difference.
Now what?

@walterm6, the black wire from the charger receptacle is hard wired to the OBC and I verified continuity successfully from the charger receptacle to the back of the OBC using a needle. Should I get continuity to the nut labled NEGATIVE BATTERY VOLTAGE at the back of the OBC?

Tks for your help

That’s more like it, but one thing that doesnt seem right is you said the charger only kicked up to 10 amps when you bypassed the OBC. What charger do you have? A Powerdrive 1 charger should have been running wide open at nearly 20 amps with the OBC bypassed. The OBC is the only current control for those chargers and unless the pack is already at or near a full charge the output is going to be pretty much full speed, over 15 amps.
That makes me wonder if you still have a poor connection somewhere, if you have a bad battery in the pack that’s causing a drop in charge current, or if something is going on with the charger.
More than likely the OBC is still bad since bypassing it did make the charger turn on, but it kind of seems like you may have more than one issue here.

Bloup101 · 08-13-2019, 10:30 PM

The green wire not connected was done on purpose because the gray connector has an OEM white plug in the hole where the green wire should be. I don't know why it was not connected.

Batteries are 1 month old. I was using a powerdrive2 and my 12v batteries were near 50v, is 10amp expected for 50v?

Tonight battery pack is 49.95v and I connected an older powerdrive1 and it kicked on at 9amp with the bypass. 11amps after 10 minutes. What should I expect?
Powerdrive1 is in poor shape, the red wire blade on the diode heat sink was pulled off and now I just wedged it in. Can I solder it to the heat exchanger plate?

Bloup101 · 08-13-2019, 10:58 PM

8-9 amps after 20 minutes. My bypass wire is pretty hot specialy at the metal clips. I'll try tomorrow with rings instead of clips. Wire is the same gauge as the black wire.

Bloup101 · 08-14-2019, 09:17 AM

Battery pack 53.03v after charging all night with powerdrive1. I which there was a definite multimeter test to know the OBC is bad.

Fairtax4me · 08-14-2019, 10:04 AM

Is that 53V with the OBC hooked up or bypassed?

If bypassing the OBC gets the charger to turn on, the OBC is bad. There's a few spots where a bad connection cold be possible, usually at the receptacle or battery connections, but we know those are OK since the charger operates with the OBC bypassed. The only other possibility is corrosion or loose connection where the black 10awg wire comes out of the OBC and connects at the B- terminal on the controller. IF that's clean and tight, receptacle pins are clean, and no wires/fuse are damaged on the back of the receptacle, the OBC is bad.

You could still have a bad battery. Check the voltage of each battery individually after they rest for about 12 hours. Then take the cart for a drive and check voltage of each battery while the cart is driving so the pack is under load, preferably going up-hill. If you have one or more with voltage dropping significantly lower than the others, those lower batteries are probably failing.

Bloup101 · 08-14-2019, 10:24 AM

Yes 53v with bypass, I did clean the negative terminals on the controller.
I guess bad OBC :(
Is the OBC the same on a 2007 CC Precedent?
I would remove the OBC from the 2007 and install it in the 1999 and use the smart charger on the 2007.

Sergio · 08-14-2019, 11:54 AM

Those OBC are not compatible, the old Regen II OBC provided power to the entire cart electronics on the Blue wire.

You would need that specific version to replace it, but a new smart charger is a better option.

By the way, that green wire disconnected from the OBC was to prevent Regen brake on that old Controller while still allowing dynamic brake.

Bloup101 · 08-14-2019, 03:58 PM

Thank you for all your help.
I will completly remove the OBC and jump blue and white on controller and use a smart charger.

08-13-2019, 08:59 PM	#12
WalterM6 Gone Wild Join Date: Apr 2017 Location: SE TN Posts: 2,226	Re: 1999 48v CC DS regen2 not charging Bloup101 It looks like it's wired ok but the green wire hanging out and not connected looks suspicious.

08-13-2019, 10:30 PM	#14
Bloup101 Not Yet Wild Join Date: Jul 2019 Posts: 16	Re: 1999 48v CC DS regen2 not charging The green wire not connected was done on purpose because the gray connector has an OEM white plug in the hole where the green wire should be. I don't know why it was not connected. Batteries are 1 month old. I was using a powerdrive2 and my 12v batteries were near 50v, is 10amp expected for 50v? Tonight battery pack is 49.95v and I connected an older powerdrive1 and it kicked on at 9amp with the bypass. 11amps after 10 minutes. What should I expect? Powerdrive1 is in poor shape, the red wire blade on the diode heat sink was pulled off and now I just wedged it in. Can I solder it to the heat exchanger plate?
Bloup101 Not Yet Wild Join Date: Jul 2019 Posts: 16

08-13-2019, 10:58 PM	#15
Bloup101 Not Yet Wild Join Date: Jul 2019 Posts: 16	Re: 1999 48v CC DS regen2 not charging 8-9 amps after 20 minutes. My bypass wire is pretty hot specialy at the metal clips. I'll try tomorrow with rings instead of clips. Wire is the same gauge as the black wire.
Bloup101 Not Yet Wild Join Date: Jul 2019 Posts: 16

08-14-2019, 09:17 AM	#16
Bloup101 Not Yet Wild Join Date: Jul 2019 Posts: 16	Re: 1999 48v CC DS regen2 not charging Battery pack 53.03v after charging all night with powerdrive1. I which there was a definite multimeter test to know the OBC is bad.
Bloup101 Not Yet Wild Join Date: Jul 2019 Posts: 16

08-14-2019, 10:04 AM	#17
Fairtax4me Bonafide Nincompoop Join Date: Dec 2015 Location: Charlottesburg Va Posts: 8,987	Re: 1999 48v CC DS regen2 not charging Is that 53V with the OBC hooked up or bypassed? If bypassing the OBC gets the charger to turn on, the OBC is bad. There's a few spots where a bad connection cold be possible, usually at the receptacle or battery connections, but we know those are OK since the charger operates with the OBC bypassed. The only other possibility is corrosion or loose connection where the black 10awg wire comes out of the OBC and connects at the B- terminal on the controller. IF that's clean and tight, receptacle pins are clean, and no wires/fuse are damaged on the back of the receptacle, the OBC is bad. You could still have a bad battery. Check the voltage of each battery individually after they rest for about 12 hours. Then take the cart for a drive and check voltage of each battery while the cart is driving so the pack is under load, preferably going up-hill. If you have one or more with voltage dropping significantly lower than the others, those lower batteries are probably failing.

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08-14-2019, 10:24 AM	#18
Bloup101 Not Yet Wild Join Date: Jul 2019 Posts: 16	Re: 1999 48v CC DS regen2 not charging Yes 53v with bypass, I did clean the negative terminals on the controller. I guess bad OBC :( Is the OBC the same on a 2007 CC Precedent? I would remove the OBC from the 2007 and install it in the 1999 and use the smart charger on the 2007.
Bloup101 Not Yet Wild Join Date: Jul 2019 Posts: 16

08-14-2019, 11:54 AM	#19
Sergio Gone Wild Join Date: Sep 2012 Location: Charlotte, NC Posts: 9,329	Re: 1999 48v CC DS regen2 not charging Those OBC are not compatible, the old Regen II OBC provided power to the entire cart electronics on the Blue wire. You would need that specific version to replace it, but a new smart charger is a better option. By the way, that green wire disconnected from the OBC was to prevent Regen brake on that old Controller while still allowing dynamic brake.

08-14-2019, 03:58 PM	#20
Bloup101 Not Yet Wild Join Date: Jul 2019 Posts: 16	Re: 1999 48v CC DS regen2 not charging Thank you for all your help. I will completly remove the OBC and jump blue and white on controller and use a smart charger.
Bloup101 Not Yet Wild Join Date: Jul 2019 Posts: 16

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