Powerwise 36V charger relay clicks but no hum or current on meter

japmaple

I have a Powerwise 36v charger that I have had for about 14 years it now clicks but does not come on, no hum no current shown.
I have 2 carts so I swapped over to the other charger for now while I try to troubleshoot this one.

With the multimeter set to the diode setting that gives a tone when connected I checked the the cables from the inside of the charger to the plug end. Both runs were ok.

One thing I did notice was that sometime before I got it the small red wire
that normally goes down to the cart had been routed over to one of the main connections not sure if it is positive or negative coming from the cart. I guess it eliminated the need for the tiny red wire going to the plug end.
It has been this way for 14 years.

I also checked the fuse which is not blown, gives a tone.

With the multimeter I checked the diodes with the negative on the heat sink and positive on the diode I get a reading of 531 on both. In the opposite direction it shows open. This seemed ok from what I had read but I am not an expert.

It appears to sense the voltage from the cart and turns on the AC as I can hear the relay click.

Just to make sure the relay was actually making a connection I also shorted the 2 connections on top with a screwdriver but it still did not produce any hum or current.

I do not have a capacitor tester and with everything else seeming ok I replaced that but it did not correct the problem.

Before I replaced the diodes or the board I thought I would ask some folks that are more knowledgeable. Thanks in advance for any info you could provide.
Thanks,

HB

BGW

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radioman

There are a lot of treads deal with this charger. You can use the search feature to locate them. Enter 'Powerwise charger problem' in the search window.

JohnnieB

When there is no hum when plugged into AC power, there are three possibilities.
1. Bad AC outlet.
2. Bad AC power cord.
3. Bad transformer.

Here is the manual for it.

Attached Files

PW Charger manual.pdf (3.02 MB, 0 views)

japmaple

Thanks for the manual JohnnieB, The troubleshooting and schematic sections are a big help. I will confirm I get 110v after the relay and going into the transformer primary side.
The connection from the relay to the primary looked like it had gotten hot at one point the plastic coating is a little melted.
I will try to see if the primary coil is open or shorted.
Anything else to check about the transformer to confirm it is bad?

JohnnieB

If you get continuity when you measure between the primary leads on the transformer, it is probably good.

If it is good, try bypassing the relay on the control board. When it is bypassed, the transformer should start humming the moment the AC power cord is plugged into an AC outlet.

If it doesn't, check the power cord and plug for broken wires.

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If the transformer is bad, replace the charger with a DPI Accusense: http://www.cartsunlimited.net/48v_Battery_Charger.html

japmaple

I ohmed out from the transformer side of the relay to XF and I get an open. From the schematic I expected this primary to be connected.
With the power cord plugged in I also jumped across the relay with a screwdriver and I get no hum. I guess the transformer is bad, Thank's for your help. I will keep the url for the charger when I need one.