Orange light charging 99DS

[grassors]

I have a 99DS Club car with new batteries reading 8.6V each or 51.6V fully charged. After driving it 5 minutes i get an orange blinking light on 5 seconds off 5 seconds on 25 seconds and it repeats the pattern. When i plug it in the charger comes on for 20 minutes then shuts off. After this I receive a solid orange light on the dash with the charger still plugged in. Also the highest voltage reading with the charger plugged in gets to right around 54V. I have already tried resetting the OBC, and borrowed a neighbors charger and it does the exact same thing.

Are my batteries not getting the proper charge and if not what could be possible solutions?

Thanks in Advance!

[Aflyer]

I am not sure about what I am about to tell you, others will jump in and confirm or deny.

I think that strange light activity is telling you your OBC is on it's way out. Mine was doing something similar and inconsistent like that before it just finally quit working.

I also think it should charge your batteries to more like 60 - 61 volts before shutting off.

Because your batteries are new, I would drive the car and run the batteries down and then recharge again, because after an OBC recharge it will take a few cycles to learn the new batteries. I say this because when I changed my OBC the light did more strange things for 2 - 3 charge cycles. And now it is acting normal.

Aflyer

[grassors]

After doing a little more digging around I noticed the Battery main negative is not running through the OBC. The old cable is just hanging there and the new battery cable appears to run straight to the controller. Not sure if there is some sort of sensor in the OBC pass through.

Does the battery main negative have to pass through the OBC for it to charge correctly?

I got this cart from my boss a couple weeks ago so I am new to all of this.

Thanks!

[mrgolf]

Originally Posted by grassors

After doing a little more digging around I noticed the Battery main negative is not running through the OBC. The old cable is just hanging there and the new battery cable appears to run straight to the controller. Not sure if there is some sort of sensor in the OBC pass through.

Does the battery main negative have to pass through the OBC for it to charge correctly?

I got this cart from my boss a couple weeks ago so I am new to all of this.

Thanks!

There you go.

The cable need to go through the obc to work correctly. Ask the guy you got the cart from if he did that for some reason. The obc may have problem, or he just may have put cables on cart and didn't see how to run the cable through the hole with the lug on the cable.

[NoleFan4Ever]

That is most likely it as Mr. Golf said. The new cables had the lugs already on and the person could not put it through the OBC. Just go to Advance Auto ot any place with loaner tools and get their crimper, then purchase the correct size high quality copper lug and cut of the old one, run it through the OBC and crimp the new lug back on.

The OBC will take up to a ~2 awg cable so hopefully yours is no bigger. If so, you will have to use a lug stud through the OBC to mount the cable on both sides of it so it can be hooked to your controller B- and still record energy usage.

[grassors]

Thank you all the good information! So I had military grade 2 AWG wire on the cart and it would not go through the OBC, but as suggested I did the stud through the OBC and hooked everything back up. I reset the OBC and everything seemed to take a charge. I posted the readings of fully charged 8 hours off the charger vs. just before the charger kicked off. By the way this site is awesome and has a ton of useful information.

After 8 hours off charger
8.62
8.62
8.69
8.59
8.6
8.6

Reading plugged in just before cutoff
10.35
10.38
10.40
10.40
10.22
10.19

Thanks Again!

[mrgolf]

Just think, some day you will explain to someone else what there problem is when they have the same problem.

[grassors]

Agreed

[NoleFan4Ever]

Those battery readings look great!