Powerwise shuts off early

[bobbyg75]

Not sure I'm checking diodes correctly. Should leads be connected or disconnected? I have model 28115 G04.

[JohnnieB]

To check capacitor (and transformer), you have to bypass the relay to turn on charger.
Use a short wire with male 1/4 push on connectors at each end as shown in picture.

Without it installed, voltage will be 60VAC +/- 5
If not, transformer may be bad.
IF so, connect capacitor.
With Capacitor installed, voltage will be 90VAC +/- 7
If not, Capacitor is bad.

However, you mentioned the Ammeter was jumping to 20A when charger first turns on, so transformer, capacitor and diodes are most likely good.

WHAT IS THE BATTERY PACK VOLTAGE WHEN THE CHARGER TURNS OFF????

[bobbyg75]

The voltage of the pack:

There is a ~3 second delay when it is plugged in
Running at 5a - pack at 45.5v
Just after shutoff - pack at 40.3v

Oops - makes sense that the transformer has to be calling for a charge! I'll make a jumper wire.

1) Do I disconnect the leads from the diodes for the transformer check? Are there any polarity concerns with testing at the leads?

2) To complete the diode check - are the leads connected or both disconnected?

[JohnnieB]

Oops - makes sense that the transformer has to be calling for a charge! I'll make a jumper wire.
Tape it inside charger for future use.

1) Do I disconnect the leads from the diodes for the transformer check? Are there any polarity concerns with testing at the leads?
Yes, disconnect the diodes and attach the DVM leads to the wires that were connected to them.
No, the voltage from the transformer secondary is AC, so there is no polarity.

2) To complete the diode check - are the leads connected or both disconnected?
The lead must be disconnected only on the diode being tested, but you'll be are checking the other one also, so you might as well disconnect both while you've got the wrench in your hand.

There is a ~3 second delay when it is plugged in Good, this is normal
Running at 5a - pack at 45.5v Good, pack voltage is rising into cut-off range. Transformer, capacitor and diodes are good, or this wouldn't happen.
Just after shutoff - pack at 40.3v Probably normal.

-----------------
Something is amiss here.

Your charger appears to be working normally and fully charged batteries are being charged, hence the short charge time.

What charger does your friend have?
Were the batteries partially discharged when you tried it, or were they near full charge?

[bobbyg75]

What charger does your friend have? Friends is same model as mine
Were the batteries partially discharged when you tried it, or were they near full charge?There was some degree of disharge when I used my friends charger, however I did not measure it. But his charger ran 8+ hours that evening!

[bobbyg75]

"Try discharging battery down to about 80% (37.5V) and then observe how charger reacts. Any deviation from the sequence I posted above, indicates a problem, so tell us exactly what it does." I'll hook-up the voltmeter tonight and run the cart to 37.5v and report results of charger activity.

[JohnnieB]

Maybe your charger is working normally and his is a little sick.

At this point, I would discharge the cart down to about 80% Soc and charge with your charger, observing how it reacts.
Then discharge down to the same SoC and charge with his charger, again observing how it reacts.

If there is a significant difference in charge times, I'd try switching the control board between the two and do it again.

Added:
I'll hook-up the voltmeter tonight and run the cart to 37.5v and report results of charger activity.

That should tell us if your charger is working normally

[bobbyg75]

Diodes check good

Transformer check:
w-capacitor - 92.5v
w/o-capacitor - 71.7 (chart says 65 max, but says bad transformer is lower)

Cart sat all day and was at 38.4 when I started the afternoon work.
Ran to 37.7 - its all over when driving and settles after sitting
At 5:06 plugged in at 19a
At 5:36 16a
At 6:00 4a and 45.1v
6:02 shutoff, pack at 41.1v

Whatcha think JohnnieB?

Different problem - while running cart up slight incline power stopped and cart beeped until I lifted and stepped on pedal. Continued without problem. Solenoid?

[JohnnieB]

I think your charger worked normally when you used it yesterday evening.

As for the cart stopping and beep, it could be a lot of things.
If it continues doing it, put controller in diagnostic mode and run that way.
Count the beep code the next time it fails.

[bobbyg75]

What do you think was causing the earlier problem of early shutdown? I golf tonight so will let you know how the charger acts after 18 holes. I'll also include measure of pack voltage before and after the round.