Can I fix my TC/Elcon charger myself?

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coulomb
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Can I fix my TC/Elcon charger myself?

Post by coulomb »

weber wrote: Is the output choke really thermally coupled to the heatsink like the main transformer is, or is it just mechanically mounted to it on standoffs?

It's thermally coupled:

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It's not totally clear in the photo above, but that's a 5 mm thick aluminium bar coated with thermal conductive paste. (It gets everywhere; ask me how I know.)

Image

I'm thinking that this may be the inductor on the primary side, in series with the primary winding. I base this on the fact that this inductor doesn't seem to have a voltage marking, but a large toroidal inductor nearby does. So I'd say that the toroid is on the output side, and varies in inductance and current rating depending on the output voltage and current.

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roddilkes
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Can I fix my TC/Elcon charger myself?

Post by roddilkes »

A customer of mine just alerted me to this thread.

I sent four chargers back to TC Charger that I replaced under warranty for my customers.
I was hoping they would come to the party but I now have to pay repairs on them and freight both ways, ouch. I had them in stock too long.

I also have a couple of dead ones around from my own use which I will open up and take a look. Thanks for the info. I feel a bit more confident about it now.

From reading this thread it sounds like heat buildup might be the big killer, I have noticed my own chargers get really hot and need good ventilation.


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Can I fix my TC/Elcon charger myself?

Post by Johny »

Is the one they were battling with on DIY Electric Car the same charger?
There is a link to a detailed breakdown of the charger in the first few sentences of the post.
http://www.diyelectriccar.com/forums/sh ... 90162.html

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coulomb
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Can I fix my TC/Elcon charger myself?

Post by coulomb »

Johny wrote: Is the one they were battling with on DIY Electric Car the same charger?

Same model, yes.

I've been attempting to troubleshoot Jonathanm's charger remotely, and it looks like the problem this time was one of the MOSFET driver chips. Pulses at the input, nothing at the output. It will be a while before we find out for sure, though.
Last edited by coulomb on Fri, 26 Feb 2016, 06:57, edited 1 time in total.
Nissan Leaf 2012 with new battery May 2019.
5650 W solar, 2xPIP-4048MS inverters, 16 kWh battery.
1.4 kW solar with 1.2 kW Latronics inverter and FIT.
160 W solar, 2.5 kWh 24 V battery for lights.
Patching PIP-4048/5048 inverter-chargers.

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