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Old 07-26-2015, 06:32 AM   #1
kobx
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Default Powerwise charger diagnosis

I have an ezgo 36v txt cart, with a power wise charger. The charger does not come on any more when I plug it into the cart. Usually, I'd hear a click in the charger, and then see the amps come up. Now I don't hear anything, and the charger doesn't come on. This has been an intermittent problem, but now it's just not recognizing the it's plugged into the cart.

Does anyone have any diagnosis/steps to follow for pinpointing the cause? I've never messed with chargers and want to approach this "smart", as in check the simple stuff first.

Thanks in advance for any replies.
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Old 07-26-2015, 06:33 AM   #2
kobx
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Default Re: Powerwise charger diagnosis

Just to update, the cart knows it's got the charger plug in. I say that because the cart won't power on with the charger plug installed.
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Old 07-26-2015, 06:39 AM   #3
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Default Re: Powerwise charger diagnosis

Lol, think my charger knows I'm getting ready to rip in to it, because a precise, specific jiggle on the plug and it came to life. So am I correct in thinking that it could just be something on the plug itself (like loose contacts or something?).

Anyone have a service manual or something for a 36v power wise charger?
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Old 07-26-2015, 08:11 AM   #4
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Default Re: Powerwise charger diagnosis

Clean the "Auxiliary" contact in the plug and the outside of the negative terminal in the cart's charge receptacle. That is where the charger senses the battery pack voltage.

Actually, it is the battery pack voltage that initially closes the relay in the charger, so the charger does not have to be plugged into AC power for the relay to click.

There are several different chargers with the Powerwise name on them, so I'm guessing, but her is the manual for one of the more common ones. Let me know if you have something different.
Attached Images
File Type: jpg Clean Aux contact.JPG (26.6 KB, 0 views)
Attached Files
File Type: pdf PW Charger manual.pdf (3.02 MB, 0 views)
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Old 07-27-2015, 10:47 AM   #5
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Default Re: Powerwise charger diagnosis

Besides cleaning the aux contact, a poor man's fix might be to simply wrap electrical tape around the male end of the charger plug, to get a snugger fit. shims would probably work, if the looseness isn't symmetrical.
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Old 07-27-2015, 12:00 PM   #6
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Default Re: Powerwise charger diagnosis

Johnnie B, you the man! That's exactly what I've got, and exactly what I was looking for!!

Yurtle., I thought about something like that, buts its hard to tell what is the "magic position."

Thanks again for the help/suggestions.
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Old 07-27-2015, 12:42 PM   #7
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Default Re: Powerwise charger diagnosis

You can bypass the third wire (Auxiliary contact) in the charger output cable by connecting the black wire from the control board in the charger to the transformer's center tap connection. (Powerwise 28115 chargers only - other model are wired differently.)

Attached are drawings showing the battery sense wire connected to the Auxiliary contact and to the center tap. Both do the same thing, just that the pack voltage is sensed at different places.
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Old 07-28-2015, 03:43 PM   #8
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Default Re: Powerwise charger diagnosis

Quote:
Originally Posted by kobx View Post
Johnnie B, you the man! That's exactly what I've got, and exactly what I was looking for!!

Yurtle., I thought about something like that, buts its hard to tell what is the "magic position."

Thanks again for the help/suggestions.
Try moving it up and down and side to side and watch the charger. If it "likes" one position, shim it with electrical tape to keep it in that position.
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Old 07-28-2015, 03:45 PM   #9
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Default Re: Powerwise charger diagnosis

You can also take but the plug and receptacle apart and clean up the RADSOKS (connectors) but they usually fit fairly snugly together, if no corrosion is apparent. A brush like used for cleaning guns may help, but I'm betting JohnnyB is right on the aux contact.
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Old 07-29-2015, 03:26 PM   #10
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Question Re: Powerwise charger diagnosis

Update: opened up the plug to take a look at the aux. contact, and immediately saw the problem. Some how the blade terminal had slipped of the beryllium contact, and was barely hanging on. I reconnected it, closed it up, and plugged it into the cart. Voila! Charger comes on no matter how it's jiggled....

Thanks again for all the input/advice
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