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Old 10-01-2012, 06:45 PM   #1
PBB
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Default Powerwise Charger Issues

Having an issue with a Powerwise charger. This is the older style charger with amperage meter. When I plug it into the cart, it jumps up to 20 Amps like it should and after about three seconds it kicks off.

I borrowed a buddies' charger and it charged my cart fine. I took the cover off of the charger and the board looks a little corroded. I've not been into one of these before and am looking for suggestions as to where to start.

Any ideas would be greatly appreciated. I searched for suggestions first, but was unable to come up with any similar situations in the past.

Thanks, PBB
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Old 10-02-2012, 07:32 AM   #2
JohnnieB
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Default Re: Powerwise Charger Issues

Is it a Powerwise, a Powerwise+ or a Powerwise II?

Basically, they all work the same, but different bells and whistles.
The good news is that the are built like tanks and 100% repairable.
More good news it that is is putting out 20A when it first comes on, meaning everything except the control board is good.
Even more good news is that the control board is turning it ON and OFF.
The only problem I'm seeing is that the control board is turning it off too soon.

The control board might be bad, but it could also be high resistance in a wire or connection in the charge loop or the battery sense circuit.

Measure the battery pack voltage at the main positive and negative post and not what the on-charge voltage is when the charger shuts off.
It should be in the 44V to 46V range, but probably won't be because the charger is turning off so quickly.

Then measure the on-charge voltage between the red and black wires going to the control board.
Hopefully, that will be reaching the 44V to 46V cutoff voltage.

If it does, you've just got a dirty or corroded connection someplace between the red and black wires on the control board and the main + & - posts on the battery pack. (Most likely charger related since a different charger works on the cart)

If the on-charge voltage on the red and black wire at the control board is the same as what was seen at the main +&- post on battery pack, the control board is bad.

Here is a manual for PW and PW+ chargers.
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File Type: pdf PW Charger manual.pdf (3.02 MB, 0 views)
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Old 10-02-2012, 06:11 PM   #3
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Default Re: Powerwise Charger Issues

Thanks Johnnie. It is a Std. Powerwise. I did some more reading on this last night and found another post also pointing toward the control board. I happened to have another Powerwise charger so I swapped the boards and it works as it should, so I ordered a new control board this morning.

Thanks for the info.
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Old 12-20-2012, 05:59 PM   #4
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Default Re: Powerwise Charger Issues

My Powerwise 11 stopped working yesterday. Voltage reading on the 2006 ezgo TXTE outside socket is 36v and continuity from DC plug to the opposite connections inside the charger looks good, as do the corresponding 110v connections inside the charger. Is there a check I can carry out on 'the board' and if needed who is the best source to purchase a new one from?

Continuity across the capaciter looks OK..........I am assuming it should.


Thanks
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Old 12-21-2012, 09:06 AM   #5
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Default Re: Powerwise Charger Issues

Quote:
Originally Posted by Alacartie View Post
My Powerwise 11 stopped working yesterday. Voltage reading on the 2006 ezgo TXTE outside socket is 36v and continuity from DC plug to the opposite connections inside the charger looks good, as do the corresponding 110v connections inside the charger. Is there a check I can carry out on 'the board' and if needed who is the best source to purchase a new one from?

Continuity across the capaciter looks OK..........I am assuming it should.


Thanks
It is best to start a new thread for a new problem.

However, Plug the charger into the cart without plugging it into AC power.

Do you hear the relay inside the charger click?

If not, measure the voltage on the terminals in the carts charger receptacle and the volts on the red and black wire going into the Powerwise II charger's sealed control module. (Shown in attached picture)

The voltages should be identical. If not, clean the contacts in both charger's plug and cart's receptacle.

If the relay doe click, plug vharger into AC power.
The transformer should hum.

Let us know what you find.
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File Type: jpg PW II Module.JPG (32.1 KB, 0 views)
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Old 12-22-2012, 10:59 AM   #6
Alacartie
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Default Re: Powerwise Charger Issues

Thanks for your patience.

Initial check showed same 36.2v at both locations mentioned, but no click. Out of desperation I plugged in AC, of course nothing happened until I gently tapped the black relay several times. Voila! hum kicks in, and amps swung up to 20a.

Charging at present, and if sticking relay persists am I looking at a new board?

Thanks for your help.
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Old 12-22-2012, 03:03 PM   #7
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Default Re: Powerwise Charger Issues

Try re-seating the connector on the sealed controller module with the red and black wires in it a couple times and see if that takes care of the problem. (Tapping on relay may have jiggled that connector - )

IF it persists, you might get away with just the Relay board assembly instead of the whole control board assembly.

When relay doesn't click when plugged into cart, but not plugged into AC power, check for batteri pack voltage on the two outside screw terminals on relay board.

If you've got battery pack voltage there and relay hasn't clicked , the relay board is bad.

If you don't have pack voltage there, the sealed control module is bad.

-----------
When you go looking for parts, your charger is called a Powerwise II or Powerwise 2.
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Old 12-23-2012, 10:39 AM   #8
Alacartie
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Default Re: Powerwise Charger Issues

Thanks again for taking your time on this.

Checked the outside 2 screws.......No power, but I do have the same 36.5v power between the small red and black wires going into the main power board.

Somewhere I am reading that connecting the 2 wires together that go into the relay will get me going again until I can locate a new circuit board.........???

Any comments...?

Thanks
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Old 12-23-2012, 11:15 AM   #9
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Default Re: Powerwise Charger Issues

Sounds like the control module is bad.

Bypassing the relay will turn on the charger, but it will stay on forever.

Fortunately, the PW-II uses a ferroresonant transformer design and it is next to impossible to overcharge a battery pack with it, even when hot-wired.

It would be best to shut off the charger when the On-Charge battery pack voltage reaches about 46V, or no more than about 12 hours.

Note: all the control module does is turn the charger on and off, the charge curve is designed into the matched transformer and capacitor pair.
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Old 12-23-2012, 03:33 PM   #10
Alacartie
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Default Re: Powerwise Charger Issues

JohnnieB.........YOU ARE THE MAN !!!

Thanks a whole bunch for walking me through this.

From: An aging neophyte.
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