Damn Chargers!

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Paul9
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Damn Chargers!

Post by Paul9 » Tue, 14 May 2019, 12:05

Hi people,

After having two chargers blow simultaneously I bought two new KPES chargers. I installed one and hooked it up to the existing wiring in the car. The existing wiring consists of 3 prong connector under the petrol cap connected to an on-off switch connected to a 15amp circuit breaker connected under the car to an IEC connector at the front of the car which connects to the IEC connector on the charger.

I hooked it all up, plugged in the extension lead, turned the switch on and nothing happened.

I assumed the wiring or connectors in the car must be stuffed. So using an IEC adaptor I connected a 10watt desk lamp. Worked fine. I then hooked up a 150watt cleaner and it worked fine. I then hooked up a 2400 watt heater and it worked fine. I then hooked up the charger again and nothing happened.

I concluded that it must be the charger that is at fault.

I took the extension lead and hooked it, through an IEC adapter, directly to the charger (not through the vehicle wiring) and it works fine!

From the above I assume the car wiring is fine as it handles from a 10watt light to a 2400 watt heater without any problems.
I assume the charger is not the problem because, when I connect it straight to the wall socket (not through the vehicle wiring) it works fine.
But when I connect the charger through the vehicle wiring it just sits there - no fans, no lights, no charging!

Any help much appreciated!
Paul

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Richo
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Re: Damn Chargers!

Post by Richo » Tue, 14 May 2019, 12:25

Controller surge current through the breaker is the likely problem.
Also is the breaker a breaker or RCD or combo?

A pic from under your car at those bits might help.
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Paul9
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Re: Damn Chargers!

Post by Paul9 » Tue, 14 May 2019, 12:46

Thanks Richo

Just before I go have a bo-peep at the breaker I am confused. While the controller and the breaker are both part of the vehicle's wiring, they are not part of the charging circuit? Or are they? I don't understand.

Sorry - just showing my lack of knowledge!

Thanks
Paul

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Richo
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Re: Damn Chargers!

Post by Richo » Thu, 16 May 2019, 13:05

I'm under the impression you get mains from your house, plug it into the "fuel" port which then goes through an ON/OFF switch and a circuit breaker and then to the charger at the front of the car which then connect to the traction battery.
The traction battery then connects to the controller and finally the drive motor.
BUT only ONE of the charge circuit OR the drive circuit can be ON - not both at the same time.

So the breaker and on/off switch are really the only stressed parts between the charge port and the charger at the front.

So you tested the mains wiring in the car using 10W lamp (no surge), 150W cleaner (minimal surge), 2400W (no surge), 2000W+ Charger(high surge)
And it only fails on the last one.

My guess is the breaker...

I could be wrong but I'd expect a pic would solve that.
Help prevent road rage - get outta my way! Blasphemy is a swear word. Magnetic North is a south Pole.

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Johny
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Re: Damn Chargers!

Post by Johny » Fri, 17 May 2019, 05:44

My 2c worth. The IEC connector is not plugged in all the way at the charger.

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Richo
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Re: Damn Chargers!

Post by Richo » Fri, 17 May 2019, 12:28

Paul9 wrote:
Tue, 14 May 2019, 12:05
10watt desk lamp....150watt cleaner...2400 watt heater and it worked fine.
How many of these things actually used all 3 lines (Earth)?
Possibly an earth leakage problem.

Unplug your mains and charger from the car.
Test the resistance between the each of the 3 pins of the mains charge port on your car and the chassis.
Help prevent road rage - get outta my way! Blasphemy is a swear word. Magnetic North is a south Pole.

Paul9
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Re: Damn Chargers!

Post by Paul9 » Sun, 19 May 2019, 09:04

Thanks very much Richo and Johny,

I will get my electrician brother over to help me (or more correctly - me help him) with an "electrical diagnosis" during the week. I will show him your opinions.

Of the three things I tested, the 10 watt lamp and the 2400 watt heater had earth pins. The 150watt cleaner did not have an earth pin.

I had been doing my testing with a 15amp extension lead onto the 10amp 3 pin connector at the back of the car. Thinking that the 10 amp earth pin may not have been connecting with the 15 amp socket on the lead, I substituted a brand new 10 amp extension lead and repeated my tests. Unfortunately I got exactly the same results as my first tests.

Thanks again,
Paul

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