Search found 3199 matches

by coulomb
Today, 09:06
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

The original text for this post is lost, unless an archive can be retrieved later. But the image is the only important part. I find this image very useful for "deciding where to dig" into the black gunk. Many thanks to Diyelectriccar users KennyBobby and PDove for creating it. Use your browser cont...
by coulomb
Today, 08:59
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

I'm repairing a charger that has a direct short at the output of the bridge rectifier. It looks like it has to be one or both of Q7 and Q8, the PFC MOSFETs. I've never had these fail yet, and have never seen a part number for them, so I pulled one of them from a dead charger: Q7Q8 MOSFET.jpg It's an...
by coulomb
Today, 08:57
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

I struggled to replace a transformer today. I remembered the solution was something to do with very small pieces of Blu-Tack, but I was trying to place the nyloc nut with pliers. Eventually it came to me that you use a Philips screwdriver to place the nut, and attach the nyloc nut to the end of it w...
by coulomb
Today, 08:53
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

Now some repairs possible without removing the PCB . This one is replacing the 150 ohm pre-charge resistors, which often get burned up through various mishaps. In my case, I needed to replace the wire-wound resistors (from a previous repair, actually just getting clearance to replace the input relay...
by coulomb
Today, 08:51
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

It seems I never posted about the measurements possible without removing the PCB . I'll place them here. It's hard to jam a multimeter probe at the bridge leads, at least while the heat-sink clamp is in place. Fortunately, the line end is accessible through the junction of the two long ends of the p...
by coulomb
Today, 08:47
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

I finally settled on these replacements: Aus: https://www.digikey.com.au/product-detail/en/ohmite/OX151KE/OX151KE-ND/823910 USA: http://www.digikey.com/product-detail/en/ohmite/OX151KE/OX151KE-ND/823910 http://media.digikey.com/photos/Ohmite%20Photos/OX151KE_sml.jpg They're only 1 W continuous power...
by coulomb
Today, 08:45
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

... I could never understand why the manufacturer stuck with carbon composition types that burned up so badly whenever ... It seems that my guess was wrong. Here is one of the original 150R pre-charge resistors split apart with a chisel: Inside pre-charge Rs.jpg I should have realized that they wer...
by coulomb
Today, 08:43
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

Original post by Pdove: Yes, kennybobby and I did that calculation on the first couple we repaired. They all had these resistors burnt to a crisp. We puzzled over a way to power up the viper before the relay closes instead of going through these resistors but we never tried anything. It's a very co...
by coulomb
Today, 08:42
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

I'm at Weber's house testing the repaired charger (so far so good). But before charging, we decided to check for crackling sounds (using his far superior ears). Yes, the new after-bridge capacitor was making a very similar sound to what the original capacitor was, when it wasn't being very noisy. Bu...
by coulomb
Today, 08:40
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

It's possibly obvious, but since it just happened to me, I thought I'd point out a problem that can happen when reassembling the heat-sink clips: Dont clip like this.jpg If you managed to leave it in this condition, the heat-sink clip would short out all the MOSFET drain connections. This is conside...
by coulomb
Today, 08:35
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

I remind you that, although the sound went away suddenly while we were still trying to narrow it down, that relay was in the quadrant that we'd narrowed it to, and when I listened right at the relay (and only there) I could hear a very quiet sound that was of the same character as the louder crackl...
by coulomb
Today, 08:32
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

I must be the only schmuck attempting to repair these chargers at the moment. I got all the way to testing with a real battery recently, when I decided to pull the plug before it connected (last time when it turned on the output relay was when the MOSFETs blew again). I did this because I heard the ...
by coulomb
Today, 08:27
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

Having failed to find anything wrong with the capacitors C38 (large electrolytic), and C2/C46 (small blue ceramic capacitors) in the charger I'm repairing, I've decided to take the advice of a colleague and attempt to separate the gate control signals from the drain/source output signals. Last time ...
by coulomb
Today, 08:22
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

This photo was obtained after much effort: heating and carefully scraping off yellow gunk, while attempting to retain as much as possible of the solder mask, and removing white gunk (silicone) from C38. C2 and C46 are also difficult to remove, both because they are covered in yellow gunk, but also b...
by coulomb
Today, 07:49
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

Attached is the desaturation schematic for the Elcon/TC chargers, as nearly as I can figure it. Thanks is due to Weber, for giving me the clue that this part of the schematic is probably about desaturation protection. When the lower MOSFETs are on, the 1K resistors (R59 and R63) pull C36 up to one d...
by coulomb
Today, 07:45
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

I'm fairly confident now what the SOT23 devices marked A1t are: BAW56 high speed dual diodes, available from Newark and no doubt other suppliers. It's confusing because some of them have D designators (as you'd expect from a diode or dual diode), and some have "Q" designators (as you'd expect for a ...
by coulomb
Today, 07:39
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

This is not the latest version of this post. There may be a later one archived, accessible at a later time. Warning: if the mains input is connected to actual mains, the "GND" mentioned here is at lethal potential to the ground pin of the mains, and your body. In other words: GND is HOT! I believe ...
by coulomb
Today, 07:22
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

This post from user Ruudi: Hello Thank you very much for the trouble you have seen and info you have been sharing here for this type of charger. I have two 8kW tcchargers one is on my car and working well, witch I use if I charge at charging station from mennekes connector witch is here 3 phases 3 ...
by coulomb
Today, 07:16
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

For those working on the higher voltage chargers, another little tip (see photo). Without this, I found that the little PCB would rise up with the screw, and the screw would not go into the heatsink. It was a two person job replacing the diode stack, and required the patience of a saint. But I got t...
by coulomb
Today, 07:13
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

I have another theory about how the bridge rectifier may be failing. This one is also a bit of a long shot, I think. It could be when the user *reconnects* the charger, after the main capacitor voltage has decreased significantly, *but before* the 12 V power supply drops out. So the pre-charge resis...
by coulomb
Today, 07:09
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

I'm doing another repair. Classic burned-up pre-charge resistors. This one also has the bottom half of the bridge shorted (both diodes connected to the negative terminal). This sounds familiar; I wonder if this is a common pattern? When the bridge shorts like that, then the AC input is shorted past ...
by coulomb
Today, 07:08
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

I've got a working 156V (13S flooded cells - 180V 11A max) 2Kw unit that I swapped the transformer and inductor from a 2Kw 120V (160V Max) unit - but have run into troubles with trimming the output voltage. Ooh - a transformer transplant! We've thought about that, but I don't think that's been done...
by coulomb
Today, 07:06
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

I think Paul and i were thrown by the Q designation on the pcb and were trying to make them transistors. Yes, it's strange that half the diodes are designated as Ds, and half as Qs :confused: I think we have a unit here that resists repair also--replaced numerous chips and bits which were taken out...
by coulomb
Today, 06:51
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

Re: TC/Elcon 2013 Charger Troubleshooting and Repair

I thought I posted this elsewhere, but I can't find it. When re-assembling an Elcon/TC charger after having removed the main PCB from the heatsinks, it's important to use a suitable tool to prevent this sort of problem: Elcon charger MOSFETs 004 sm.jpg Note how the nearest MOSFET has been twisted, a...
by coulomb
Today, 06:43
Forum: Batteries, charging, management and monitoring
Topic: TC/Elcon 2013 Charger Troubleshooting and Repair
Replies: 24
Views: 47

TC/Elcon 2013 Charger Troubleshooting and Repair

This information was previously posted to DiyElectriccar.com here: https://www.diyelectriccar.com/forums/showthread.php?p=452281#post452281 Coulomb's index I've decided to put an index here to what I consider to be the more useful posts in this thread. Yes, it's mainly for my own use, but others may...