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Elcon buzzing

1849 Views 4 Replies 3 Participants Last post by  kennybobby
I have an ELCON PFC 2000+ I've been using for two years (first year with lead, then reprogrammed last year for lithium). Aside from stupidly popping the AC fuse once, I've been happy with it.

Recently I've noticed the sound of the charger having more buzz or crackle when charging. So far, I've had no problem charging, but I'm wondering if it's normal or if I should be fixing some underlying problem; or just be prepared for it to die ;).

My car is here: http://www.evalbum.com/3854 , I'm using 38 x 130ah CALBs for a 120v nominal car (normally ends at 131v ... 3.45 per cell) and I'm using a Lithiumate Lite BMS.

Thanks - Dan
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There is a low-level 12 volt power circuit inside those units that supplies power to the digital board plus pulls the input relay closed to turn the unit on. If that 12v supply fails for some reason then the ac power will burn up the bypass resistors around the relay that are used to bootstrap start the charger. Sometimes the relays burn up also.
Also the units have Line and Neutral wired/labelled incorrectly such that the fuse is on the Neutral side.
Not sure what is causing the buzzing sound, but there are two large transformers/inductors on the high voltage output side that would be the likely source. Here's a link to the analog circuits: http://www.diyelectriccar.com/forums/showthread.php?t=89470
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