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Old 09-06-2014, 12:52 PM   #1
Drrhein
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Default Powerwise charger not charging

I know this is a subject that has been beat to death but the problem I'm having is somewhat different. 36V cart.

The guy has a DCS cart that he ran the batteries down - I read 34.8 pack voltage, not good.

We can't get the charger to start even though I was fairly sure the charger only needed to see 27.5 to start. We tried another charger and still the same, no charge. I can get it to charge by bypassing the logic board relay in the charger but the charger stops as soon as we remove the wire.

So I did that and got the pack voltage up to 35.8 but that doesn't seem to help.

Ideas anyone? For now I'm charging with the jumper across the relay in the hope the charger will start working when we get the pack voltage up.

We've had a lot of storms around here lately and I'm a bit leery of trying his charger on another cart for fear of screwing up that one.

Ideas anyone?
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Old 09-06-2014, 01:30 PM   #2
JohnnieB
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Default Re: Powerwise charger not charging

Sounds like the charger's control board is not sensing the cart's battery pack.

EZGO battery sensing is typically done via the third wire in the output cable, the Auxiliary contact in the charger plug touching the outside of the negative radsok in the cart's charge receptacle.

If you cannot get the charger to see the battery via the Auxiliary contact, you can eliminate the third wire in the output cable by connecting the black wire on the control board to the negative output wire inside the charger.
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Old 09-06-2014, 03:05 PM   #3
Drrhein
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Default Re: Powerwise charger not charging

The bypass worked as described. That got me feeling better about the charger and I tried it on another cart and it worked fine.

I wanted to fix it and as two different chargers didn't work, and bypass did, I took the cart connector apart and lo and behold there was a mud dauber's nest inside both pins keeping the charger plug from seating all the way (even though it felt seated and seemed in all the way by the label) and the third wire (red wire) was just short of making contact maybe by a thousandths of in inch.

Oh well...

Oh, and the seating label was not on correctly - as when we got the plug in properly the label showed in too much, so we took it off and put it on right..
Have you ever wondered why you wasted an entire day on something so stupid -- or am I the only one who has ever done that?
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Old 09-07-2014, 07:06 AM   #4
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Default Re: Powerwise charger not charging

Quote:
Originally Posted by Drrhein View Post
Have you ever wondered why you wasted an entire day on something so stupid -- or am I the only one who has ever done that?
You are not alone by any stretch of the imagination and going to the trouble of finding and fixing an elusive problem is being conscientious rather than stupid.
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Old 10-08-2014, 09:00 AM   #5
billlisk@rocketmail.com
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Default Re: Powerwise charger not charging

Tnx, will use these suggestions to further isolate problem
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Old 02-20-2019, 10:23 AM   #6
tlr6334
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Default Re: Powerwise charger not charging

Johnny B, the fix you described above, can this be used as a permanent fix?
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Old 02-20-2019, 10:36 AM   #7
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Default Re: Powerwise charger not charging

It's electrically the same either way. So yes, it can be permanent.

Before this old post, I was about to do this, when I saw the metal contact in the charger plug was dirty, and cleaning it did the job.
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Old 02-20-2019, 11:32 AM   #8
cgtech
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Default Re: Powerwise charger not charging

The charger would function slightly more accurately in it's original configuration, as it's "view"of battery pack voltage would be taken at the cart, instead of after any drop or losses that happened in the charger connection and cable.
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Old 02-20-2019, 11:41 AM   #9
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Default Re: Powerwise charger not charging

But isn't its view discrete, rather than analog?
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Old 02-20-2019, 12:48 PM   #10
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Default Re: Powerwise charger not charging

Quote:
Originally Posted by yurtle View Post
But isn't its view discrete, rather than analog?
Explain please, I must need more coffee...
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