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Old 09-16-2018, 03:11 PM   #1
jpyoungman
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Default Issues With 36V EZGO Powerwise Charger Model 28115 G04

Good Afternoon,

I am having issues with my Powerwise Charger. I obtained it with a 36V EZGO Workhorse I got at an auction. When I first got the charger it would not click on due to a bad control board. I replaced the board and this solved the first issue. The second problem I had was with the connections going into the cart, they were very worn out and the plug had to be cocked at just the right way to get the aux contact to make a good connection to turn on the cart. I bought replacement contacts for the plug and the cart. The new plugs for the cart had white insulators around them which stopped the aux contact from making contact so I cut the copper piece off and wired it directly to the connector inside the handle. After this the cart would click on but instead of going to ~20 amps than slowly lowering it will only go to about 4 amps. I didn’t think moving the contact would create this problem because I believe it only controls the relay on the control board. I went ahead and replaced diodes, the capacitor and the fuse with the same result of only 5 amps. The carts batteries are old and should be replaced but until I get the charger behaving I don’t want to invest in new batteries and ruin them with a bad charger.

Thank you!
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Old 09-16-2018, 03:14 PM   #2
twilliams81
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Default Re: Issues With 36V EZGO Powerwise Charger Model 28115 G04

What’s the total transformer output??


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Old 09-16-2018, 03:17 PM   #3
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Default Re: Issues With 36V EZGO Powerwise Charger Model 28115 G04

I wasn’t sure the exact way to test this, but measuring from diode to diode I had 73.5V AC with and without the capacitor connected. Should I have removed the diodes before doing this test?
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Old 09-16-2018, 03:19 PM   #4
twilliams81
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Default Re: Issues With 36V EZGO Powerwise Charger Model 28115 G04

No but that does sound a little high I do believe...maybe some of the other experts on here could confirm that?


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Old 09-16-2018, 03:20 PM   #5
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Default Re: Issues With 36V EZGO Powerwise Charger Model 28115 G04

Do you think the voltage should have been different with and without the capacitor?
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Old 09-16-2018, 05:01 PM   #6
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Default Re: Issues With 36V EZGO Powerwise Charger Model 28115 G04

One more thing, I did not put the magnet back inside the plug when I reassembled everything, I cannot find what its purpose is.
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Old 09-16-2018, 07:34 PM   #7
JohnnieB
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Default Re: Issues With 36V EZGO Powerwise Charger Model 28115 G04

Measuring from Diode to Diode, you should get 60VAC +/-5VAC with capacitor disconnected and 90VAC +/-7VAC with capacitor connected.

You say you are getting same voltage with and without capacitor connected, so I'd disconnect the transformer leads from the diode and test again, just to eliminate the possibility the diode and rest of circuit have an influence.

Also, the charger should not be connected top cart for test. (Bypass relay to turn charge on)

Attached are a text document explaining the tests and a schematic showing them.

----------
The magnet opens the reed switch inside the cart's charge receptacle, disabling cart while on charge.
Attached Images
File Type: jpg Transformer-Capacitor test - Text-1.jpg (367.7 KB, 0 views)
File Type: jpg Transformer-Capacitor test.JPG (66.2 KB, 0 views)
File Type: jpg Charger receptacle - Reed Switch.JPG (73.5 KB, 0 views)
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Old 09-17-2018, 05:53 AM   #8
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Default Re: Issues With 36V EZGO Powerwise Charger Model 28115 G04

Thanks for the great info JohnnieB, I will test and get back to you.
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Old 09-17-2018, 06:55 AM   #9
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Default Re: Issues With 36V EZGO Powerwise Charger Model 28115 G04

I thought I had a problem with my charger. It would not go over a couple of amps. Ended up being a bad battery.


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Old 09-17-2018, 08:47 PM   #10
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Default Re: Issues With 36V EZGO Powerwise Charger Model 28115 G04

Results

Normal alignment:
Across diodes 72v Ac
Charger plug 30.63V DC (seems low)

Diodes disconnected with Capacitor:
Across transformer leads 71.7V AC

Diodes and Capacitor disconnected:
Across capacitor coil 15.8V AC
Across transformer leads 71.7V AC
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