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Unread 05-24-2012, 05:06 PM   #1
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Default PowerWise II Charger Convert to SB50 Plug Issue

Hi Guys,
I'm trying to convert the Powerwise II charger to the SB50 (marathon style) plug. The charger is new and was working on the D (txt style) plug. Taking the ends out and putting them into the new SB50 plug gives me nothing, no transformer click, nothing at all. With the D plug, it works fine and clicks on within seconds then starts charging.

I jumped the relay and got the transformer to hum, but nothing click on.Is there some wiring I need to play with in order to get this to work? If so do you have it handy to make my life a little easier? Or can this simply just not be done? Thank you all for your time!

Titus
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Unread 05-24-2012, 05:27 PM   #2
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Default Re: PowerWise II Charger Convert to SB50 Plug Issue

what cart was this Powerwise II charger working on before you cut the plug and changed it to the SB50 ??
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Unread 05-24-2012, 06:15 PM   #3
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Default Re: PowerWise II Charger Convert to SB50 Plug Issue

Charger is brand new out of the box, tested on a TXT, works fine, changed the plugs to a marathon, no longer works.
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Unread 05-25-2012, 06:51 AM   #4
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Default Re: PowerWise II Charger Convert to SB50 Plug Issue

Are there any photos out there on how the wiring needs to be?
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Unread 05-25-2012, 07:19 AM   #5
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Default Re: PowerWise II Charger Convert to SB50 Plug Issue

Sounds like the battery sense wire isn't connected, or connected wrong.

Battery sense wire is the smaller of the three wires in the output cable. With the D plug, it is connected to the auxiliary contact (Item 36 in drawing) and touches outside of Negative Radsok when plugged into cart.

Either connect it to the Negative (Black wire) terminal in the SB-50, or inside the charger, connect the black wire coming from the control board to Ammeter.

Here are a couple of schematics showing a PW-II type charger with three wire and with two wire output cables connected.
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Unread 05-25-2012, 09:04 AM   #6
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Default Re: PowerWise II Charger Convert to SB50 Plug Issue

I tried the wiring from the above diagrams with jumper wires before hard wiring everything and no clicks, no nothing. I took the black wire coming from the cntrl board, where it connects to the red, put a 3 way splitter into that, to the ammeter, and got nothing. then just the black straight to the ammeter, nothing.
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Unread 05-25-2012, 09:54 AM   #7
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Default Re: PowerWise II Charger Convert to SB50 Plug Issue

Quote:
Originally Posted by FF Titus View Post
I tried the wiring from the above diagrams with jumper wires before hard wiring everything and no clicks, no nothing. I took the black wire coming from the cntrl board, where it connects to the red, put a 3 way splitter into that, to the ammeter, and got nothing. then just the black straight to the ammeter, nothing.
Connect the black wire from control board to ammeter only. Leave red wire going into output cable disconnected.

Also, could be the battery pack voltage is too low. Has to be above about 28V to make relay click.

BTW - The charger does not have to be plugged into an AC outlet to get relay to click, the cart's battery pack supplies the power to energize the charger's relay initially. Then the output from the charger holds it closed until pack voltage reaches 44-46V.
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Unread 05-25-2012, 10:00 AM   #8
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Default Re: PowerWise II Charger Convert to SB50 Plug Issue

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Originally Posted by FF Titus View Post
.............. then just the black straight to the ammeter, nothing.
Oops, missed the last part.

Either battery pack is too low or control board is blown.

With balck wire connected to ammeter only, measure between Black and Red wires on control board. If between about 30 and 45 volts, I suspect the control board is gone. Outside that range, something is amiss with the battery pack.
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Unread 05-25-2012, 11:14 AM   #9
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Default Re: PowerWise II Charger Convert to SB50 Plug Issue

Got it! I tried a different car and it worked perfectly! Thank you all so very much, made my life much easier today :)
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Unread 05-25-2012, 11:49 AM   #10
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Default Re: PowerWise II Charger Convert to SB50 Plug Issue

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