Warning Light

[Ribber]

Originally Posted by Sergio

The gray wire is how the OBC communicates with the external charger.

If there is no fuse on the gray wire, the gray wire is disconnected or the gray wire is run to pack negative, that communication does not exist.

Are you saying the cart charges with the gray wire disconnected?

If Your charger works is because the relay has been by-passed inside the charger or has some other modification done to it and most likely it is not charging correctly.

The fuse was removed and the grey wire is spliced.
The charger does communicate with OBC. I'm going to assume the fuse blew and someone cut it out and spliced.
I replaced the relay and heatsink in charger, so it's not been modified.

[Sergio]

The fuse is a protection device should the "voltage suppression" diode in parallel with the charger relay coil fail.

That 8 amp min current when the charger shuts OFF could be when the OBC is switching from the "Bulk" to the "Absorption" phase, which should eventually go all the way down to 3 amps.

If the SCR circuit inside the OBC failed to regulate the charging current at that point (current is not regulated at the "Bulk" phase), You would get that blink pattern for "abnormal charging cycle".

Some of the early OBC models that had a lighter color casing You could see a "brown" spot near where the cable runs through the OBC. That "brown" spot was where the SCR underneath over-heated.

Keep an eye on your battery voltages and range, but You may want to start budgeting for a new smart charger.

[Ribber]

Originally Posted by Sergio

The fuse is a protection device should the "voltage suppression" diode in parallel with the charger relay coil fail.

That 8 amp min current when the charger shuts OFF could be when the OBC is switching from the "Bulk" to the "Absorption" phase, which should eventually go all the way down to 3 amps.

If the SCR circuit inside the OBC failed to regulate the charging current at that point (current is not regulated at the "Bulk" phase), You would get that blink pattern for "abnormal charging cycle".

Some of the early OBC models that had a lighter color casing You could see a "brown" spot near where the cable runs through the OBC. That "brown" spot was where the SCR underneath over-heated.

Keep an eye on your battery voltages and range, but You may want to start budgeting for a new smart charger.

I don't see a brown spot, but what your saying sounds like what's happening. Like I've said, the charger/OBC 'acts' weird sometimes (relay trips, no communication when plug in, etc.) I'll reset the OBC (disconnect pack negative 15 minutes) and it will work normally, except for switching off at 8 amps.
I'm going to save up for a DPI.

[jjance]

I'm going to save up for a DPI.

I wouldn't start saving. You need to put it on the card or else you'll be saving for a new set of batteries too. Crown Batteries don't like Club Car chargers. Google Crown Batteries vs Club Car.