Need help with Powerwise charger sending max redline amps

[jubal]

So I recently replaced the diode board, 50amp fuse, and relay board on my charger to get it going. When I plug it in now it just immediately goes from 0 to 30+ on the charger instead of sitting at 15 on the ammeter like it used to. I've been scared to even leave it plugged in longer than 10 seconds because I don't want to fry anything. The replacement board I used is from golf cart king. Does anyone have any idea what I did wrong to create this issue?

I wish I could give more information about my golf cart but the serial number plate which was in the passenger side dash was removed before I ever got the cart. I believe it's a circa 97-03 ezgo txt.

[cgtech]

You may have installed the incorrect diodes?

[JohnnieB]

Which Powerwise charger? see attached images.


The relay (also called control) board has nothing to do with the amps the charge puts out, other than turning the charger on and off.

Amps out are determined by the matched ferroresonant transformer and boost capacitor pair along with the voltage level existing on the battery pack it is connected to.

30A is a bit high, so the capacitor may be out of tolerance or the transformer is bad. Also attached are how to test transformer and capacitor.

[jubal]

Thanks for the replies folks!

Originally Posted by cgtech

You may have installed the incorrect diodes?

Interesting. I didn't change out just the diodes but instead the heat sink bar. The replacement one required drilling a new hole as a mounting point because they didn't exactly line up, the instructions provided said to do that. It says I installed a 'Heat Sink Part Number 3426'. It has a 3rd center cap that I left alone.

Originally Posted by JohnnieB

Which Powerwise charger? see attached images.


The relay (also called control) board has nothing to do with the amps the charge puts out, other than turning the charger on and off.

Amps out are determined by the matched ferroresonant transformer and boost capacitor pair along with the voltage level existing on the battery pack it is connected to.

30A is a bit high, so the capacitor may be out of tolerance or the transformer is bad. Also attached are how to test transformer and capacitor.

Mine is your 2nd picture with the silver top half and black bottom half on the face. Same industrial model - 28115 G04. I'll try to test out the transformer and capacitor and get back to you. Thanks again.

[JohnnieB]

Here's a schematic and service manual for a 28115.

[cgtech]

Originally Posted by jubal

Thanks for the replies folks!



Interesting. I didn't change out just the diodes but instead the heat sink bar. The replacement one required drilling a new hole as a mounting point because they didn't exactly line up, the instructions provided said to do that. It says I installed a 'Heat Sink Part Number 3426'. It has a 3rd center cap that I left alone.

Hmm, sounds right, that's what I usually end up doing too.