[EVDL List]

Hi,

I am installing a PFC30 (purchased used) and the limits led comes on as soon
as I start turning up the current. It does not deliver any amps to the
battery.

The setup is basic, a small 118.8V lithium pack, 120V AC source, and nothing
is plugged into the regbus port.

This is what I am doing: amps knob set to 0; pack connected, turn on PFC
breakers, set the voltage trim by turning it counter-clockwise until limits
comes on, then slightly clockwise until it goes out. Then when I start
turning up the amps knob, the limits light comes on right away, and I don't
see any amps at all on the meter.

I don't know what voltage it was set for by the previous owner, so I counted
the number of turns from the stop at CCW to where the limits light goes
on/off, and it is about 4 1/2 - 5 turns, which should be about right (I
think?) for a 120V pack.

If the volts trim is turned clockwise further, it doesn't help.

What am I doing wrong? Does the regbus need to have any wires set in this
base configuration? The switch pack is set the same as the picture in the
manual, which seems to be correct.

Suggestions?

Thanks,
Wayne



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[EVDL List]

You don't say, but do you have the charger connected to a load? It must be
connected to a load before turning it on and turning up the current or you
can develop too high voltage in the charger and damage it. If it is
connected to your pack, one possibility is that the output fuse is blown.
This is an L50S 50 fuse mounted on the back inside the charger. You can
pull the cover and check if for continuity.



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[EVDL List]

[quote] tomw <xxx@xxx.xxx> wrote:

> You don't say, but do you have the charger connected to a load? It must be
> connected to a load before turning it on and turning up the current or you
> can develop too high voltage in the charger and damage it. If it is
> connected to your pack, one possibility is that the output fuse is blown.
> This is an L50S 50 fuse mounted on the back inside the charger. You can
> pull the cover and check if for continuity.


Also note that a blown output fuse creates a no-load condition. There are
some here far more experienced than I who assert that switching on a PFC
charger with no load is a near guarantee of letting the smoke out. It's
not a cheap repair. Those same people generally assert that design-wise,
this is an unnecessary downside of the PFC line.

PFC chargers are very powerful for their size, but they are *not*
consumer-grade devices. You must know their weaknesses and work around
them. Lack of no-load protection, lack of GFCI and lack of thermal runaway
protection come to mind. If you don't know what you're doing, prepare to
learn the hard way.

Chris
LeSled is for sale!
http://www.evalbum.com/274
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[EVDL List]

Tom -

Good call. It was a blown output fuse inside the charger. I installed
a small 8A test fuse and am able to charge just fine at 5A. Not sure why
the 50A was blown, but it's working as expected now, and will hopefully
continue to once the replacement 50A is in.

Thanks,
Wayne




tomw wrote
>
> You don't say, but do you have the charger connected to a load? It must
> be connected to a load before turning it on and turning up the current or
> you can develop too high voltage in the charger and damage it. If it is
> connected to your pack, one possibility is that the output fuse is blown.
> This is an L50S 50 fuse mounted on the back inside the charger. You can
> pull the cover and check if for continuity.
>




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[EVDL List]

Chris,

I have no doubt that there are no load conditions that will fry the charger.
I was concerned that this might be the case. From what I've read, it is
more likely to fail if there is a substantial current flow when a disconnect
occurs. At that point, I would expect the voltage to shoot up trying to
maintain the set current, causing an over-voltage condition.

Fortunately in my case, there was no damage, and it is able to charge the
pack. So an open load is not necessarily a guaranteed charger failure, but
clearly, it is a condition that should be avoided.

Thanks,
Wayne


Chris Tromley wrote
>
> [quote] tomw &lt;tomofreno2000@&gt; wrote:
>
>> You don't say, but do you have the charger connected to a load? It must
>> be
>> connected to a load before turning it on and turning up the current or
>> you
>> can develop too high voltage in the charger and damage it. If it is
>> connected to your pack, one possibility is that the output fuse is blown.
>> This is an L50S 50 fuse mounted on the back inside the charger. You can
>> pull the cover and check if for continuity.
>
>
> Also note that a blown output fuse creates a no-load condition. There are
> some here far more experienced than I who assert that switching on a PFC
> charger with no load is a near guarantee of letting the smoke out. It's
> not a cheap repair. Those same people generally assert that design-wise,
> this is an unnecessary downside of the PFC line.
>
> PFC chargers are very powerful for their size, but they are *not*
> consumer-grade devices. You must know their weaknesses and work around
> them. Lack of no-load protection, lack of GFCI and lack of thermal
> runaway
> protection come to mind. If you don't know what you're doing, prepare to
> learn the hard way.
>
> Chris
> LeSled is for sale!
> http://www.evalbum.com/274
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[EVDL List]

The PFC also lacks isolation.
But it is a unique and highly sought after charger.

[quote] Chris Tromley <xxx@xxx.xxx> wrote:

> On Sun, Aug 5, 2012 at 10:27 AM, tomw <xxx@xxx.xxx> wrote:
>
>> You don't say, but do you have the charger connected to a load? It must be
>> connected to a load before turning it on and turning up the current or you
>> can develop too high voltage in the charger and damage it. If it is
>> connected to your pack, one possibility is that the output fuse is blown.
>> This is an L50S 50 fuse mounted on the back inside the charger. You can
>> pull the cover and check if for continuity.
>
>
> Also note that a blown output fuse creates a no-load condition. There are
> some here far more experienced than I who assert that switching on a PFC
> charger with no load is a near guarantee of letting the smoke out. It's
> not a cheap repair. Those same people generally assert that design-wise,
> this is an unnecessary downside of the PFC line.
>
> PFC chargers are very powerful for their size, but they are *not*
> consumer-grade devices. You must know their weaknesses and work around
> them. Lack of no-load protection, lack of GFCI and lack of thermal runaway
> protection come to mind. If you don't know what you're doing, prepare to
> learn the hard way.
>
> Chris
> LeSled is for sale!
> http://www.evalbum.com/274
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[EVDL List]

[quote] Wayne Krauth <xxx@xxx.xxx> wrote:

> Chris,
>
> I have no doubt that there are no load conditions that will fry the
> charger.
> I was concerned that this might be the case. From what I've read, it is
> more likely to fail if there is a substantial current flow when a
> disconnect
> occurs. At that point, I would expect the voltage to shoot up trying to
> maintain the set current, causing an over-voltage condition.


Digging back in my memory banks, I'm fairly certain disconnecting the
output under load was not the issue that got people talking (though that is
certainly not advisable). It was switching on under no load. I do
remember now though, that the risk is reduced if the amps knob is turned
down to minimum on a no-load start. So get in the habit - turn the amps
knob down every time you switch off!

Chris
LeSled is for sale!
http://www.evalbum.com/274
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