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Old 09-26-2018, 10:17 PM   #1
Carts4you
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Default Powerdrive 3 charger problem

We have replaced the rectifier (small black block with four terminals) and relay assembly on charger. It was operating fine. We had one cart with a bad obc so we decided to jump the relay and use to charge the batteries on the car temporarily. It was disconnected 4 hours later. Two days later, once you connected the charger to AC the rectifier would heat up and created some smoke. The ammeter started vibrating between 0 - 5 amps, this without it being connected to cart. We replaced the rectifier and eliminated the jump of relay and now it does not operate unless we connect to golf car. However, the ammeter still vibrates between 0-5 and does not operate correctly. What could be cause for this? The fuse is not blown.
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Old 09-27-2018, 12:10 AM   #2
NoleFan4Ever
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Default re: Powerdrive 3 charger problem

Usually a Powerwise is associated with an EZGO...... Is it an EZGO charger or a Powerdrive charger?
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Old 09-27-2018, 06:47 AM   #3
twilliams81
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Default re: Powerdrive 3 charger problem

If it’s a powerDRIVE charger which model is it? 2? 3?


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Old 09-27-2018, 09:25 AM   #4
tony.loyola
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Default re: Powerdrive 3 charger problem

My apologies. It is a power drive three charger.


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Old 09-27-2018, 09:25 AM   #5
tony.loyola
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Default re: Powerdrive 3 charger problem

Quote:
Originally Posted by NoleFan4Ever View Post
Usually a Powerwise is associated with an EZGO...... Is it an EZGO charger or a Powerdrive charger?


It is a power drive charger my apologies


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Old 09-27-2018, 09:33 AM   #6
Sergio
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Default re: Powerdrive 3 charger problem

The ammeter vibrating without being connected to the cart is very unusual.

Make sure the positive wire that goes to the DC plug is by itself on one side of the ammeter, the other side will have 2 wires, one to the bridge rectifier and the other to the relay.

It looks like the bridge is bad again and you lost half of it.

The best solution is to upgrade to the 2 separate rectifier boards.

If You replace the square bridge again, in addition to making sure the wires go to the correct tabs, you need to clean the surface on the chassis where the bridge contacts it and apply heatsink paste.

That bridge gets pretty hot and without proper heat management it will burn again.
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Old 09-27-2018, 09:57 AM   #7
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Default re: Powerdrive 3 charger problem

Sergio brings up a great point about the PowerDrive 3 chargers. The earlier versions were equipped with a square rectifier that was later eliminated and replaced by a double diode strip setup for the newer PD3 chargers. It's far superior and much more reliable. The OEM conversion kit for this is #103517401 and is a very easy conversion. As for your ammeter, there's no reason why it should be moving at all unless the charger is on. The charger shouldn't turn ON unless you've plugged the DC cord into the cart. I know you mentioned you installed a relay in the charger. Was it a PowerDrive 3 relay that was built onto the little green circuit board, or did you retro-fit something else?
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Old 09-27-2018, 12:18 PM   #8
Fairtax4me
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Default re: Powerdrive 3 charger problem

The rectifier has failed again. A failed rectifier can allow current to pass without the charger plugged into the cart. If the new rectifier was installed improperly or was installed without thermal transfer grease between its base and the mounting surface it could have overheated and fried. If you don't have thermal transfer grease you can use silicone di-electric grease.

I'd get the upgrade kit from David.
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Old 09-27-2018, 12:23 PM   #9
Sergio
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Default re: Powerdrive 3 charger problem

Quote:
Originally Posted by Fairtax4me View Post
The rectifier has failed again. A failed rectifier can allow current to pass without the charger plugged into the cart. If the new rectifier was installed improperly or was installed without thermal transfer grease between its base and the mounting surface it could have overheated and fried. If you don't have thermal transfer grease you can use silicone di-electric grease.

I'd get the upgrade kit from David.
Sorry but this is not correct, there is no AC power to the transformer unless the relay closes and the relay is powered by the golf cart.
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Old 09-27-2018, 03:23 PM   #10
Fairtax4me
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Default re: Powerdrive 3 charger problem

He said the relay was bypassed to get it to charge without the OBC. With the DC cord unplugged no current should flow, but the coils will still be energized. If the rectifier fails, relay bypassed, the rectifier can pass current to ground without being plugged into the cart.

Reading through again, its possible one of the coils is open or has a bad connection, or the diode is incorrectly wired. At this point I think you need to check AC output of the coils at the rectifier and double check your connections.
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