I just finished upgrade from lead to Li, and changed out my charger and dc-dc because I went from 96v to 120v. I installed a little Elcon 1500 charger... and after the first day driving around I had a really weird thing happen.
I was grabbing an 'opportunity charge' while guest lecturing at the local community college about Electric Vehicles, and we had just moved to going thru the car. About half-way thru walking the class thru the system I wanted to show the contactor open/close, so I quick unplugged the charger, hopped in the car, turned in on - fine, turned it off - fine, turned it right back on to make contacter close again, and BAM.... blew my big ferraz 400amp fuse.
The fuse was installed 'close' (maybe 1/2 inch) to the charger physically, in-line between front pack and rear. I had a 'cover' over exposed lugs/bolts made from bike inner tube slipped over the line.
I am using the charger interlock output running thru to pot-box->KSI. I did NOT use optional key-switch wire on charger, I joined it with the AC power in as instructed...
everything else seems fine, and once I found it after class I was able to just take it out and run home fuse-less. controller, dc-dc, everything seems working fine. Charger seemed fine and charged pack up just dadny last night.
what could have happened? any guesses?
