Powerwise Bad Board

[TexasDave]

I have a 36v EZGO, powerwise charger had a bad board and bad capacitor. Changed both and now the board still will not work. I am assuming the new board was bad too. I am currently charging with a jumper. But I am consumed with worry that my cart will explode due to overcharging. I have searched for the exact answer to my delima which is, "what is typical charge time for a 50% depleted set of batteries"? I have a DVM. So I guess volt could let me know when they are charged?

Was in bed last night about to doze off and remembered the CHARGER WAS STILL RUNNING. At that time it had been 4 hours, I disconnected to be safe.

I am hesitant to buy a new board. What else could I check?

its hard to set a time on when the batteries are fully charged as a lot of verables are involved
a muilti meter would help you with monitoring pack voltage
let them charge to 44.5v then shut it down
a quick fix i used before was a electric wall plug timer .. i set it for 6 hrs

if charger is working with the jumper then my guess is bad board .. can you get replacement under warranty ?
video i like about power wise charger

Fix Golf Cart Ezgo Powerwise Charger - YouTube

Fix Golf Cart Ezgo Powerwise Charger - YouTube

[TexasDave]

With the DVM are the locations shown on the photo where I test?

Have since got new batteries and made some cables.

that is correct

[JohnnieB]

For starters, a ferroresonant transformers design charge, such as the Powerwise, isn't very likely to raise the on-charge voltage high enough to damage a healthy battery pack. You would have to exceed 2.8VPC (Volts per Cell), which is 50.4V for a 36V pack, to approach damaging voltage levels and even if you left a Powerwise charger with the relay by-passed on the batteries for 24 hours, I have my doubts it would raise the on-charge voltage that high.

Secondly, the back-up timer in a working Powerwise charger shuts it off if the on-charge voltage does not reach the predetermined cut-off voltage that is typically in the 44V to 46V range within 16 hours. Therefore letting it charge up to 16 hours ought to be relatively safe.

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Since your charger is charging the batteries with the relay by-passed, the transformer, capacitor, diodes, ammeter and wires/cables in the charging loop are good or in reasonable good condition.

The problem is either the control board OR the battery sensing circuit. (Something not mentioned in the video, and the items he pointed to are diodes rather than resistors as he called them and they are good in your charger.)

To check the battery sensing circuit:
Measure and record the battery pack voltage at the battery pack's main + & - terminals.
Measure the voltage at the radsoks (Female terminals) in the cart's charge receptacle. It should be identical to the pack voltage.
With the charger plugged into cart, but NOT plugged into AC power, measure the voltage one the red and black wire going to the control board. (Doesn't matter if the control board is the one or two piece variety, there is only on set of red and black wires)
That voltage should also be identical to the battery pack voltage.
If it is, the control board is bad.
If it isn't, the battery sensing circuit is bad.

Let us know what you find and we'll go from there.

BTW, here is the manual.

[TexasDave]

Forgot to mention, I went from two boards to one. Not sure it that makes a difference.

Thank you VERY much.

[JohnnieB]

Originally Posted by TexasDave

Forgot to mention, I went from two boards to one. Not sure it that makes a difference.

Thank you VERY much.

Not if the conversion kit was installed right.

[blackhatmav]

Need to revive this thread. Same concern here. New board and cart side connector from charger. Charger works when relay is jumped. Pack voltage is 36.8. Voltage at connector is 36.8. Voltage at control board red wire to black wire is 0 with charger connected at cart only.
Any help is welcome.

[JohnnieB]

Sounds like the battery sense circuit isn't sensing the battery pack voltage.

The pack voltage is picked up on the outside of the negative radsok in the charge receptacle by the Auxiliary contact in the charger's plug. Item 36 on attached drawing.

Just some cleaning might fix the problem.

There is also an inline connector on the black wire from the control board inside the charger.

[yurtle]

The photo in post #2 shows the "proper" way to discharge the capacitor.