Battery Charging Troubleshooting

[NoleFan4Ever]

I am not Bruce or Walt, but I will try to educate you a little in their absence. The OBC counts energy units used (going out) thru the pack negative cable that goes through the OBC and registers it. When you plug the charger into the cart, the OBC will again count the energy units being sent to the pack (going in) by measuring the current thru the pack negative cable going through the OBC. The OBC returns approximately 110% of the energy consumed during use. At the end of the cycle the OBC will signal the charger to turn off. The communication you question comes between the OBC and the charger. The OBC tells the charger when to charge, how to charge, and when to turn off.

[Sergio]

I am assuming You have a Series cart, big lever FNR switch.

If You post a picture of the Solenoid, we can check the wiring.

Just keep in mind that any "small gauge wires" on the Solenoid big post must be of the big post connected to the pack positive battery post.

[pharmsc]

I do have a series Cart (Lever FNR Switch) will take some pictures tomorrow in daylight I believe that there are 4 separate connections to the small terminals on the solenoid with Two connections on each side. Thanks all for staying with me on this!! much appreciated!

[pharmsc]

I have attached two pictures of my solenoid rewiring Please tell me what I did wrong Thanks in advance for your help much appreciated

[pharmsc]

photos attached

[NoleFan4Ever]

First all the large battery lugs should be on the bottom (touching the solenoid) and then the smaller gauge wires on top of them. This includes the diode and pre-charge resistor being above the lugs.

Next, your 2 small terminals are correct in regards to wire orientation, but on the 2 large terminals you have a red wire on the large post with the yellow cable. This should be on the large post with the red cable. That is either for your OBC or buzzer.

And the diode on the 2 small terminals should have the banded/striped side closest/facing the small terminal with the white/black wire and NOT the yellow wire. I cannot tell from your picture but you need to check and verify.

[pharmsc]

Many thanks I will verify and address these issues today. I should replace the pre-charge resistor as the wires have separated from the lugs and I secured them by trapping them under the lugs and tightening them down. Hopefully my miswiring did not ruin the OBC!

[NoleFan4Ever]

Originally Posted by pharmsc

-snip-
Hopefully my miswiring did not ruin the OBC!

It would not hurt it, but it would not have power until the solenoid closed in and transferred power across the bridge.... (There is also a fuse in that harness you can check)

[pharmsc]

[pharmsc]

SUCCESS! Thanks to all for their expertise! Today the charger tapered off and I have 54 volts across the pack at rest!