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Old 04-02-2013, 06:46 PM   #1
mike@norrislake
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Question EZgo PowerWise Battery Charger Problems

I have an EZ GO Power Wise charger. It is the older style with two circuit boards. I have replaced the two with one new small board. It will not cycle on when I plug in the cart. If I jump the relay it will charge but of course will not turn off. Any thoughts are welcome.
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Old 04-03-2013, 07:21 AM   #2
JohnnieB
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Default Re: EZgo PowerWise Battery Charger Problems

Plug charger into cart without plugging AC power cord into AC power.

Measure voltage between red and black wires going to control board.
Voltage should be identical with the cart's battery pack voltage.

If not, it is most likely a dirty connection between the Auxiliary contact in the charger's output plug and outside of negative radsok in cart's receptacle.
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Old 04-03-2013, 01:16 PM   #3
mike@norrislake
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Default Re: EZgo PowerWise Battery Charger Problems

I have 37.9 volts in battery and 0 on the red and black on the board. I assumed you mean the two posts labeled red and black with red and black wire soldered to the board. I also followed the red wire back to the switch and there is no break. I do get the same volts on the black and white at the transformer. Any other thoughts? Thanks for your help.
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Old 04-03-2013, 01:44 PM   #4
JohnnieB
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Default Re: EZgo PowerWise Battery Charger Problems

Quote:
Originally Posted by mike@norrislake View Post
1. I have 37.9 volts in battery and 0 on the red and black on the board.
2. I assumed you mean the two posts labeled red and black with red and black wire soldered to the board.
3. I also followed the red wire back to the switch and there is no break.
4. I do get the same volts on the black and white at the transformer.
5. Any other thoughts? Thanks for your help.
1. The control board is not sensing the battery pack, so charger doesn't turn on.
2. Yes, IF the red wire (+) connects to the heat sink with the two diodes on it and the black wire, connects to the third wire in the output cable.
3. What red wire connected to what switch? Maybe we aren't talking about same charger. Is this the charger you have?
4. The transformer and associated voltages are not in the battery sensing circuit.
5. If possible, post pictures of your charger's control board showing the way it is wired.
Attached Images
File Type: jpg PW charger.jpg (153.5 KB, 0 views)
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Old 04-04-2013, 09:07 PM   #5
mike@norrislake
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Default Re: EZgo PowerWise Battery Charger Problems

My Charger looks just like your pic. The red wire to the switch was from the receptacle on the cart. The red ran from the back of the receptacle to the switch on the device that reverses the the motor....I think. ....I may have followed the wire incorrectly in the harness.
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Old 04-05-2013, 03:53 AM   #6
JohnnieB
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Default Re: EZgo PowerWise Battery Charger Problems

You followed that wire correctly, you were just tracing the wrong wire.
The wires in question are in the charger, not in the cart.

The red wire from the control board in the charger connects to the aluminum plate the diode assembly is mounted on. The aluminum plate is connected to the cart's main positive battery terminal via the heavy white wire in cart's charge receptacle after going through the ammeter and fuse in the charger.
(The small white wire that connects to the red wire inside the cart that you traced, is an entirely separate circuit. It disables cart when the charger's plug is plugged into cart's charge receptacle, but has nothing to do with the actual charge process.)


The black wire from the control board in the charger connects to a wire in the charger's output cable, which in turn connects to the Auxiliary contact the the charger's output plug.

The Auxiliary contact touches the outside of the negative radsok (terminal), which is connected the the carts main negative battery terminal via the heavy black wire.
Attached Images
File Type: jpg PW Charger Schematic - Batt sense traced.JPG (47.8 KB, 0 views)
File Type: jpg Clean Aux contact.JPG (26.6 KB, 0 views)
File Type: jpg Charger receptacle with top off.jpg (71.7 KB, 0 views)
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Old 04-05-2013, 08:53 PM   #7
mike@norrislake
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Default Re: EZgo PowerWise Battery Charger Problems

I did clean the contact on the plug from the charger. I did not do anything on the cart, it will be a day or so before I can work on the cart end and I will post the results. Thanks so much for your help. I get over to WV every fall to run the Gauley during Gauley Season. Love WV. I am in OH.
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Old 04-06-2013, 03:53 AM   #8
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Default Re: EZgo PowerWise Battery Charger Problems

I'm not into whitewater rafting, but I have watched people get wet in water that had flowed through the Gauley when they base jumped off New River Bridge.
My skydiving days are ancient history, but my oldest boy came up from FL to do it a couple times and I was tempted.

I live a stone throw from where water that started in the Gauley flows into the Ohio.
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Old 04-07-2013, 06:32 PM   #9
mike@norrislake
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Default Re: EZgo PowerWise Battery Charger Problems

JohnnyB I did as you suggested and cleaned the terminals and contacts on the recepticle and guess what! I plugged in the charger and it clicked on and is charging. Thank you for your help and friendship. I learned something new today so the day is not lost.
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Old 04-08-2013, 03:26 AM   #10
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Default Re: EZgo PowerWise Battery Charger Problems

Your old control boards may be good, if you just had dirty contacts.
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