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-   -   Powerwise II Parts? (https://www.buggiesgonewild.com/showthread.php?t=186238)

TxMasterBoat 08-17-2022 09:21 PM

Powerwise II Parts?
 
Where are you getting parts for your Powerwise II chargers? Mine stoped charging, no hum or buzz so Iím thinking the board is shot. Are they pretty simple to replace? New batteries were installed last year.

Capt. Lenny 08-18-2022 05:47 AM

Re: Powerwise II Parts?
 
I have done a search online before and found a board by using the model number of the charger. Quite often I have found a bad capacitor. You can visually look for a bad capacitor by looking at the top between the connections. If it's concave (popped up) it is usually bad. Easy to replace, all you have to do is find the right value.

Capt. Lenny 08-18-2022 07:20 AM

Re: Powerwise II Parts?
 
Here is a good video for testing a capacitor with a volt meter.
https://www.youtube.com/watch?v=QOlhktSd9l8

kgsc 08-18-2022 07:37 AM

Re: Powerwise II Parts?
 
Try jumping the two heavy wires on the relay board and see if the charger starts. If so unplug it from the wall and check the small wires for pack voltage. If there replace the board. If not check the receptacle

radioman 08-18-2022 10:07 AM

Re: Powerwise II Parts?
 
In addition to the previous suggestions are the batteries in the cart up to voltage? Low battery voltage can cause charger not to charge. Do you hear the relay on the circuit board in the charger click a second or so delay after you insert charging plug into cart? Is the AC receptable powered? Just a few obvious observations first before you tear into charger.

TxMasterBoat 08-18-2022 09:58 PM

Re: Powerwise II Parts?
 
Iíve been using a neighbors charger, so I know the charger is the issue. Iíll try the tests yíall mentioned, thanks for the help guys!

TxMasterBoat 08-26-2022 02:58 PM

Re: Powerwise II Parts?
 
1 Attachment(s)
Quote:

Originally Posted by Capt. Lenny (Post 1904813)
Here is a good video for testing a capacitor with a volt meter.
https://www.youtube.com/watch?v=QOlhktSd9l8

I watched the video and discharged the capacitor and tested it. I couldnít tell what the value because it is pretty rusted over. Does this mean itís bad?

TxMasterBoat 08-26-2022 03:00 PM

Re: Powerwise II Parts?
 
Quote:

Originally Posted by radioman (Post 1904892)
In addition to the previous suggestions are the batteries in the cart up to voltage? Low battery voltage can cause charger not to charge. Do you hear the relay on the circuit board in the charger click a second or so delay after you insert charging plug into cart? Is the AC receptable powered? Just a few obvious observations first before you tear into charger.

Batteries in the cart are good. I donít hear any clicking or humming when plugged in. The charger is plugged into a power strip with a couple other things that work.

kgsc 08-26-2022 03:06 PM

Re: Powerwise II Parts?
 
Did you jump the relay in the charger? Or check the small wires going to the relay board for pack voltage?

TxMasterBoat 08-26-2022 03:58 PM

Re: Powerwise II Parts?
 
Quote:

Originally Posted by kgsc (Post 1906079)
Did you jump the relay in the charger? Or check the small wires going to the relay board for pack voltage?

That was going to be my next test after the capacitor.

Capt. Lenny 08-26-2022 05:50 PM

Re: Powerwise II Parts?
 
I canít see what you have the meter set on but if you followed the instructions in the video then Iím thinking itís bad. Theyíre cheaper than a board so might not hurt to give it a try.

sthreatt 08-26-2022 06:23 PM

Re: Powerwise II Parts?
 
In a Powerwise 2 the relay is mounted on a small circuit board and is a relatively cheap and easy replacement. But if the "timer" board that it screws to goes bad the price of that can make you swallow your bubblegum.

radioman 08-26-2022 07:12 PM

Re: Powerwise II Parts?
 
Take your capacitance meter to a place that sells capacitors and test one of them. A typical capacitor range would be around 8 Mfd 600 volts AC. Take your suspect capacitor with you and compare reading with known good capacitor.

kgsc 08-27-2022 11:08 AM

Re: Powerwise II Parts?
 
Quote:

Originally Posted by TxMasterBoat (Post 1906086)
That was going to be my next test after the capacitor.

If the transformer isnít making any noise the capacitor wonít matter.. Just sayin..

radioman 08-27-2022 11:39 AM

Re: Powerwise II Parts?
 
Did you listen for the relay in the charger to click when you plug charger into cart? This relay is powered by the cart battery voltage. I hear mine click a few seconds after I plug it into cart. This relay completes the AC path to the transformer. No click no hum.

radioman 08-27-2022 11:55 AM

Re: Powerwise II Parts?
 
Quote:

Originally Posted by kgsc (Post 1906189)
If the transformer isnít making any noise the capacitor wonít matter.. Just sayin..

Maybe but sometimes other components that fail cause other problems. Anyway if you are going to check a capacitor troubleshooting you need to know your test equipment can be trusted. Capacitors also short out.

kgsc 08-27-2022 12:16 PM

Re: Powerwise II Parts?
 
1 Attachment(s)
I completely agree.. That said you can test the cap all day long but if the transformer doesnít power up you are wasting your time..

If you end up needing a cap attached is a pic of one that will work..

radioman 08-29-2022 04:53 PM

Re: Powerwise II Parts?
 
To TxMasterBoat,
Capacitor may not be the problem but it would be a good test to get familiar with your meter. The video you watched shows how simple it is. You don't have to know what the value of the capacitor is to measure it. If you are going to fix this thing you need to review what others have suggested. Typical capacitors in these type of chargers are in the range of 8 to 20 Microfarads. Post a pix of your meter so those of us are trying to help you select the right settings on you meter to make some measurements of why the transformer don't hum when you plug it in without you having to plug it in to AC. I am not real familiar with this charger. I had the opportunity to repair only one (mine). It had low current output and proved to be a weak capacitor.

radioman 09-03-2022 12:12 PM

Re: Powerwise II Parts?
 
My Powerwise Industrial charger (Model 28115G01) has developed a problem. It has been working about 7 years with no problem. I know the charger is bad because I have another more modern Powerwise 2 works. I got a chance to review some of the advice I have offered on this post. My charger suddenly developed low output current and a more than normal hum when it turns on. First thing I checked was the capacitor. It was badly corroded and rusted but it measured 19.8 Microfarads. A substitute capacitor did not change anything. Both diodes checked good. The only abnormal indication was the secondary of the transformer got warm after a few minutes of operation. Neither diode was more than warm to the touch. This charger also has a circuit board mounted in front of the diode heat sink may be the problem. My GUESS is the transformer is bad. I am not going to replace it. I did make one observation with the capacitor disconnected. The charger would not hum when powered up and plugged into cart.

kgsc 09-03-2022 12:59 PM

Re: Powerwise II Parts?
 
1 Attachment(s)
Went and found an old thread with the charger manual and diagnostics. With the capacitor connected the transformer should be putting out high 80s to low 90s AC. If not it is bad.

radioman 09-03-2022 03:38 PM

Re: Powerwise II Parts?
 
Quote:

Originally Posted by kgsc (Post 1907209)
Went and found an old thread with the charger manual and diagnostics. With the capacitor connected the transformer should be putting out high 80s to low 90s AC. If not it is bad.

Thanks for the info. I will check it out and post results.

radioman 09-04-2022 11:26 AM

Re: Powerwise II Parts?
 
Quote:

Originally Posted by kgsc (Post 1907209)
Went and found an old thread with the charger manual and diagnostics. With the capacitor connected the transformer should be putting out high 80s to low 90s AC. If not it is bad.

I found the problem using your information. Transformer secondary voltage with diodes
disconnected measured 88 volts AC with equal voltage of 44 volts between each leg and center. I decided to check the diodes again while I had them loose. One of them checked open the other good. The failed diode had a loose top post. I reconnected everything except the one bad diode and got the exact symptom, louder than normal AC hum and low output current of a few amps. Any idea what the specs or number of the diode is? I could not read the numbers due to corrosion. I will review the manual you sent for specs. This old charger will probably be around a few more years. Thanks again kgsc!

kgsc 09-04-2022 02:10 PM

Re: Powerwise II Parts?
 
Which diode assembly do you have? Is it just a barrel mounted to a board? Or an assembly?

If it is just the barrel look on the old ones and see if there is an arrow on the side

TxMasterBoat 09-04-2022 02:52 PM

Re: Powerwise II Parts?
 
1 Attachment(s)
Quote:

Originally Posted by kgsc (Post 1906189)
If the transformer isnít making any noise the capacitor wonít matter.. Just sayin..

Just to make sure, is this the two heavy wires to jump?

kgsc 09-04-2022 03:01 PM

Re: Powerwise II Parts?
 
No.. Well I donít think so. Need a picture of the other side of the transformer. Those look like the common white wires. These would be black going into the top of the relay.

TxMasterBoat 09-04-2022 03:37 PM

Re: Powerwise II Parts?
 
1 Attachment(s)
Quote:

Originally Posted by kgsc (Post 1907375)
No.. Well I donít think so. Need a picture of the other side of the transformer. Those look like the common white wires. These would be black going into the top of the relay.

This is what the other side looks like. Do I need to jump the relay?

TxMasterBoat 09-04-2022 10:23 PM

Re: Powerwise II Parts?
 
Quote:

Originally Posted by kgsc (Post 1907375)
No.. Well I donít think so. Need a picture of the other side of the transformer. Those look like the common white wires. These would be black going into the top of the relay.

Ok, sorry I donít always get a chance to work on my stuff with 2 babies. I jumped the relay and it started to buzz as soon as I plugged the charger into the wall. Then I plugged it into the cart and the charger showed about 20 amps. Bad relay?

radioman 09-05-2022 09:13 AM

Re: Powerwise II Parts?
 
Did you check for pack voltage (around 36 volts DC) between the two small wires on the relay as kscg suggested in posts #4 and 9? This voltage comes from the cart's battery pack. You can check for it without charger being plugged into AC.

kgsc 09-05-2022 11:30 AM

Re: Powerwise II Parts?
 
What he said. With the charger plugged into the cart check for voltage on the small red and black wires at the top of that board. If there replace the relay board

TxMasterBoat 09-05-2022 09:26 PM

Re: Powerwise II Parts?
 
Quote:

Originally Posted by kgsc (Post 1907466)
What he said. With the charger plugged into the cart check for voltage on the small red and black wires at the top of that board. If there replace the relay board

Yes Iím getting 36v there. Does the relay board give signal to the relay itself?

TxMasterBoat 09-05-2022 09:39 PM

Re: Powerwise II Parts?
 
1 Attachment(s)
The relay looks like itís pretty burned up. Thanks for all your help so far! Where can I find a replacement board at?

sthreatt 09-06-2022 07:21 AM

Re: Powerwise II Parts?
 
Quote:

Originally Posted by TxMasterBoat (Post 1907546)
The relay looks like itís pretty burned up. Thanks for all your help so far! Where can I find a replacement board at?

eBay, about $45 . Had to replace one about two weeks ago.

TxMasterBoat 09-06-2022 03:35 PM

Re: Powerwise II Parts?
 
Quote:

Originally Posted by sthreatt (Post 1907569)
eBay, about $45 . Had to replace one about two weeks ago.

Awesome thanks you! Do you happen to have the part number still?

sthreatt 09-06-2022 03:54 PM

Re: Powerwise II Parts?
 
Quote:

Originally Posted by TxMasterBoat (Post 1907675)
Awesome thanks you! Do you happen to have the part number still?

Manufacturer Part Number:
603197 5957

TxMasterBoat 09-07-2022 09:51 AM

Re: Powerwise II Parts?
 
Quote:

Originally Posted by sthreatt (Post 1907676)
Manufacturer Part Number:
603197 5957

I ordered one last night, thanks again!

I jumped the relay to charge it last night, and the batteries now show 39v. But the battery indicator on the cart is still blinking low battery. Is there a reset or something I need to do?

radioman 09-08-2022 12:06 PM

Re: Powerwise II Parts?
 
Quote:

Originally Posted by kgsc (Post 1907367)
Which diode assembly do you have? Is it just a barrel mounted to a board? Or an assembly?

If it is just the barrel look on the old ones and see if there is an arrow on the side

The diode is a stud mount 1N1188A. Diode arrived today and installed. Charger works great. Things I learned and observed: When checking diodes in circuit disconnect both. Diodes usually short out but not always. One open diode causes loud hum in transformer and low amps output. The transformer secondary gets extremely hot if left connected to cart charging at low rate.

TxMasterBoat 09-09-2022 02:33 PM

Re: Powerwise II Parts?
 
Quote:

Originally Posted by kgsc (Post 1907466)
What he said. With the charger plugged into the cart check for voltage on the small red and black wires at the top of that board. If there replace the relay board

The new relay board came in. I installed it and still doesnít charge. Same issue it seems like, no buzz and no sounds at all.

kgsc 09-09-2022 03:02 PM

Re: Powerwise II Parts?
 
Could be the board that controls the relay. Go back to the diagnostic manual and see what you find.

TxMasterBoat 09-09-2022 06:52 PM

Re: Powerwise II Parts?
 
Also something Iíve noticed, when I jump the relay to charge the cart, it start out at about 20 amps on the charger gauge, and slowly trickles down to 10 amps. I donít know if that has anything to do with my problem.

radioman 09-10-2022 08:35 AM

Re: Powerwise II Parts?
 
Using a jumper to bypass relay to charge the batteries is a bad idea. The current drop you notice may be a result of overcharged batteries. The bad relay you removed had a melted place around one of the power connections. This may have been caused by a poor connection with the mating connection. Suggest you double check for 36 volts across the small wires again when you plug charging cable into cart.


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