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Unread 09-26-2015, 01:45 PM   #21
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Default Re: 2003 Club Car DS Questions - 1st time cart owner

If it would have happened in the first 5 minutes, it did not turn off and on again.
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Unread 09-27-2015, 02:25 PM   #22
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Default Re: 2003 Club Car DS Questions - 1st time cart owner

I'm installing a battery gauge, and while i had the dash panel out, I popped the battery light out, and in moving it, it came on, it now goes on and off, on for 10+ seconds, off for about 3 seconds, then back on, turning the key on doesn't seem to change it, plugging in the charger doesn't seem to change it. Thoughts?
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Unread 09-27-2015, 06:32 PM   #23
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Default Re: 2003 Club Car DS Questions - 1st time cart owner

The 10 seconds ON, 4 seconds OFF, blink pattern is a failure of the OBC or charging system.

Do a quick test to make sure the charge relay is not sticking once activated.

Plug the charger and let the cycle begin, unplug the DC cord and make sure the charger goes OFF (no humming and no voltage on the DC plug).
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Unread 09-27-2015, 08:46 PM   #24
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Default Re: 2003 Club Car DS Questions - 1st time cart owner

The charger definitely completely shuts off when I unplug the DC cord from the cart.

I was pushing on the back of the battery light when it started working, so I'm guessing the connection inside the light itself was bad, and it has probably been going off for some time.

What's the likelihood of a connection being bad or something? Is that typically a pretty reliable indicator of a bad OBC?

I just went out and disconnected the charger (which was still charging at almost 0 amps), and after disconnecting the charger the light flash seems to be 30 seconds on, 3 seconds off.
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Unread 09-27-2015, 10:57 PM   #25
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Default Re: 2003 Club Car DS Questions - 1st time cart owner

Ok, one more update, it's been off the shcrger for a couple hours, flashing is:

3 seconds on
3 seconds off
18 seconds on
3 seconds off

this just repeats continuously, sound to me like the OBC is bad.

Thoughts?
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Unread 09-28-2015, 07:51 AM   #26
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Default Re: 2003 Club Car DS Questions - 1st time cart owner

It does appear the OBC is malfunctioning as many of its functions are not working properly (Self test, Charger relay control, cart lockout, charger cycle end).

If You already reset the software in the OBC by disconnecting the pack power for more than 10 minutes, You either need to change the OBC or buy a new smart charger (DPI accusense) that does not need an OBC.
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Unread 09-28-2015, 08:06 AM   #27
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Default Re: 2003 Club Car DS Questions - 1st time cart owner

Thanks Sergio, the charger I have does drop in current as the batteries take a charge, I have a timer that I was going to install on the charger my father in law could select up to 24 hours of charge time. I'm not sure i'll get a new OBC in time to get it installed before I deliver the cart.

All of this being said, here are my questions.

1. Will monitoring and limiting the amount of time the charger is on be a viable option moving forward? The charger is responding to the state of charge of the batteries and dropping the current delivered.

2. I can get a Lester OBC for around $200, if I put it in, what is the likelihood this will fix the problem? Is there anything else I should be checking before I buy one?

3. Is this charger an option?

http://www.ebay.com/itm/Club-Car-48-...f225d0&vxp=mtr
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Unread 09-28-2015, 09:56 AM   #28
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Default Re: 2003 Club Car DS Questions - 1st time cart owner

Quote:
Originally Posted by wilsonsk View Post
Thanks Sergio, the charger I have does drop in current as the batteries take a charge, I have a timer that I was going to install on the charger my father in law could select up to 24 hours of charge time. I'm not sure i'll get a new OBC in time to get it installed before I deliver the cart.

All of this being said, here are my questions.

1. Will monitoring and limiting the amount of time the charger is on be a viable option moving forward? The charger is responding to the state of charge of the batteries and dropping the current delivered.

2. I can get a Lester OBC for around $200, if I put it in, what is the likelihood this will fix the problem? Is there anything else I should be checking before I buy one?

3. Is this charger an option?

http://www.ebay.com/itm/Club-Car-48-...f225d0&vxp=mtr
Two things one is with that charger you would have to bypass the OBC and it is only a 5 amp charger and really kind of small to properly charge a pack when the stock charger is a 15 or more amp charger thus charging will take longer. Too small of a charger can actually shorten a batteries life span as it takes a large charger to force feed the energy back deep into the plates...

For a little over 300.00 you can get a 17 amp DPI charger and bypass the OBC and really take good care of those batteries
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Unread 09-28-2015, 10:02 AM   #29
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Default Re: 2003 Club Car DS Questions - 1st time cart owner

Agreed The initial charge cycle (bulk replenishment) requires amperage equal to nearly 10% of the battery's total capacity.

5 amps is equivalent to a finishing cycle not charging! Gonna be a lot of disappointed people with these cheap chargers.

5amps won't stir the sediment up off the bottom of the cells = soon the battery fluid becomes stratified with all the heavy elements sitting at the bottom no longer active in the exchange which is the useful power. Sad thing is the damage may take a year or more to really become noticeable - then it may be irreversible.
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Unread 09-28-2015, 11:29 AM   #30
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Default Re: 2003 Club Car DS Questions - 1st time cart owner

Ok, I have an answer on the 5 amp charger, so my options are:

1. Put a timer on the charger I have, never let it go past 16 hours (it is reducing the output current as the batteries charge). Least out of pocket cost.

2. Spend $200 on a new OBC. Next lowest in cost, my current charger will work, how often do these things fail?

3. Spend $300 on a new charger. Most expensive but probably long term most reliable

I'm on a time constraint (about 5 days) and to some extent a budget. Will using a timer do the trick? It appears that the OBC is not shutting the charger off, but the current is going down like it should, so the timer would basically take the place of the OBC not shutting the charger off.
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