Powerwise Charger confusion

Commander2100

I've been digging into this cart trying to see what needs fixing and I have issues with the charger. I have found plenty of information on the 28115-G04 but I have the 28115-G06 (picture #1) and can find nothing. They look very similar but one thing I know is different is there's an extra relay (picture #2 and #3) that's mounted to the plate right above the circuit board. Not exactly sure what it is for. In all of the diagrams I've seen there are only a positive and negative wire coming from the charger. Mine has a 3rd wire (picture#5). It connects to the shifter switch? (picture #4) not sure of the technical term. I am guessing this 3rd wire has something to do with the extra relay in the charger. Anyways, I have determined the circuit board needs to be replaced but as far as the other relay and 3rd wire, I'm not even sure where to start troubleshooting to determine if it's good or not. Can anybody enlighten me?

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BGW

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cgtech

Not 100% sure (only 90%), but i bet the difference is your charger was designed to be a "onboard charger" mounted to the cart that only gets its 110v unplugged, not its 36v wires. Most common for stretch & work carts.

Commander2100

It is mounted right under the driver seat next to the battery tray. It has a regular 3 prong plug cord attached to it. The other wires are hardwired to the batteries I'm assuming. Everything was disconnected when I got it and no batteries. All new batteries installed just trying to figure out how to hook everything back up and make it run.

JohnnieB

The additional relay mounted on the heatsink above the control board disables the cart when the charger is plugged into AC and connects B+ to the control board.

The heavy white wire from the charger to the battery pack's main positive terminal connects B+ to the heatsink in the charger. The Blue wire inside the charger connects the heatsink (B+) to the C terminal on the relay.

When charger is unplugged from AC power, B+ is routed to the microswitches on the F/R assemble via the relay's NC contacts. (When a off-board charger is used, the voltage to the microswitches comes from the reed switch)

When charge is plugged into AC power, B+ is routed to the Red wire on the control board via the relay's NO contacts.

There is a Pin-Out for the relay on the label shown in picture-2.

Since battery sensing goes through the extra relay, the charger's control board might not be bad.

Commander2100

So I bought a new board for the charger and now it works! My next question is, will the charger automatically shut off when the batteries are fully charged? The 3rd wire that goes to the microswitch and disables the cart during charging won't effect the charger's ability to automatically shut off if that microswitch is bad? I just really don't want to mess up my new batteries

JohnnieB

Whether the microswitch on the F/R assembly exists or not, doesn't change how the charger works since the microswitch receives voltage from the charger rather than the charger receiving a voltage from the microswitch.

The extra relay in the charger switches the B+ voltage on the charger's heatsink between the control board for battery sensing when charger is plugged into AC power and the microswitch input when charger is disconnected from AC power.

If the extra relay in the charger does not connect B+ to the control board, the charger will not turn on.

Commander2100

Thanks. I obviously know nothing about electric golf carts. Glad I have this site to help me out. I checked it this morning and it had shut off on it's own.