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Old 08-16-2011, 10:14 PM   #1
bigemann
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Default powerwise wiring issues

I just got a 1996 powerwise 36V charger. It doesn't shut off at all and there is no click when just plugged into my cart no matter what the voltage from the cart. I opened the charger and it is obvious that someone has been in here and they did some relay bypassing. My question is, as there are only a couple of wires I haven't figured out, on the wiring schematic I found on this site there is a wire in the lower left corner that goes nowhere and is marked "RED Battery - return" where does it go? I have a black wire from the control board that has been cut. There is no 50amp fuse anymore. There is only one wire connected to the ammeter and the black AC wire is connected directly to the transformer.
Thanks in advance for any responses.
Allen
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Old 08-17-2011, 10:03 AM   #2
JohnnieB
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Default Re: powerwise wiring issues

The "RED Battery - return" wire goes to the Aux. contact in the plug that plugs into the charger receptacle on the cart.
According to the schematic, the Red wire going the the charger plug attaches to the Blk wire coming off the control board, but without seeing it, I don't know what you've got.
Please post pictures.

If the relay is bypassed, the relay will click when the charger is plugged into an AC outlet rather than when the charger (whose power cord is already plugged into an AC outlet) is plugged into cart.

You say there is only one wire on the ammeter, if so where are the two heavy wires in the cable that plugs into to the cart attached?
One should be connected to the centertap of the transformer secondary and the other connected to the diode board via the fuse (missing?) and ammeter.
The third (Smaller) wire was discussed above.

The white (Neutral) wire in the AC power cord should connect to the transformer, but it may change colors once it goes through the power input board.
The black (Hot) wire is the one that is controlled by the relay.

You said the charger doesn't turn off, so do you get a reading on the ammeter?
Does the battery pack voltage increase when you plug the charger into the cart?

If so, it sounds like someone turned an automatic charger into a manual one.

If the transformer is okay, you can replace what is bad and/or missing and have an automatic charger that will most likely serve you well for years to come.
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Old 08-17-2011, 08:20 PM   #3
bigemann
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Default Re: powerwise wiring issues

Hey JohnnieB,

So here we go. The cart charges when plugged in, which I don't like since it should be automatic and sometimes it is forgotten which burns up my batteries.

The ammeter reads and changes as it is charging the batteries.

In the pics you'll notice the black AC wire is butt connected directly to the transformer. The white AC wire goes to the power input board. The green AC wire goes to the case.

Basically, I want to turn it into an automatic charger like it once was, but when I get the new power input board and control board (which is a single board now) I need to put all the wires back where they go and that black wire that becomes a red wire that goes to "Battery - return" is not telling me where it is supposed to go.

If you look at the url I have here you'll see in their pics a couple of red spade connectors on the left of the pic that my charger doesn't have. These may have to do with the black wire that has been cut in my charger. I can't tell where those are hooked up at.
http://server1.buggiesunlimited.com/...ic.php?t=27496
Attached Images
File Type: jpg AC plug side.jpg (60.7 KB, 45 views)
File Type: jpg back of ammeter.jpg (55.8 KB, 12 views)
File Type: jpg black wire from control board.jpg (60.5 KB, 12 views)
File Type: jpg cart plug side.jpg (64.2 KB, 11 views)
File Type: jpg down on relay.jpg (54.9 KB, 12 views)
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Old 08-18-2011, 01:43 AM   #4
Andy4639
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Wink Re: powerwise wiring issues

When you buy your new board it does away with all the other wires going to the boad on the front panel. You can remove all of it wires and all. The new board does away with all those those lights also. As for a 50amp fuse go to your local automative store and buy a inline fuse holder and some 50 amp fuses and you have the fuses now to install on the ampmeter.




The new board tells you where everything goes once you have it.
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Old 08-18-2011, 09:54 AM   #5
JohnnieB
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Default Re: powerwise wiring issues

What Andy said.

Since the charger is charging you battery manually, a new control board ought to return your charger to its original automatic operation.
When you get the new style board in, follow instructions that comes with it and remove everything that isn’t needed.
If you have trouble hooking it up, post questions/pictures here and we’ll help you figure it out.

Forgive me if I am wrong, but I suspect your background in electronics/electrical is limited and translating from schematic diagrams to the actual physical layout is difficult.

One thing that is confusing is that lines connecting things together on a schematic are electrical connections rather than wires. They may be wires, but not always and where they connect is only the same point electrically rather than physically.

Case in point. Picture 2 of 5 in your post shows only one wire connected to the back of the ammeter, yet it shows current flow when charger is plugged in to AC and attached to cart’s battery pack. The second “wire” is the aluminum panel (Heat-sink).

Two wires coming from the transformer are attached to the anodes of the two diodes and both of the cathodes are in electrical contact with heat-sink. Current flows through the heat-sink to the + post of the ammeter, through the ammeter and out the other post. Please note the other post is insulated from the heat-sink. The + output (white wire) to the charger plug is connected to this post. After passing through the battery pack, the current come back into the charger via the black wire in the output cable, which is connected to two wires coming out of the transformer (effectively creating a center-tapped secondary), completing the current path.

You will note in picture 3 of 5 that a red wire from the board in front is attached to the heat-sink on the far right about midway up. This is the B+ source for the control board.

The unattached black wire from the board in front is the B- source for the control board. Since the output cable shown in picture 4 of 5 only has two wires in it, this wire was most likely attached to the center-tap of the transformer.

Basically, when the charger is plugged into an AC outlet, but not the cart, the relay is open and the charging circuit is dead. When the charger’s output cable is plugged into the cart, the cart’s battery pack is connected to the control board. If the battery pack is above a predetermined voltage (28V?), the relay is energized and AC power is applied to the transformer primary and charging current flows in the secondary.

When the output voltage of the charger reaches a predetermined level, the control board de-energizes the relay.
Also, if the voltage does not reach the predetermined voltage within a preset time, the control board de-energizes the relay.
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Old 08-18-2011, 10:53 PM   #6
bigemann
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Default Re: powerwise wiring issues

Thanks for your inputs. I'll let you know how it goes once I get my new card. BTW know a good site for getting a decent price on the card?
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