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Discussion Starter · #1 ·
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?
 

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Discussion Starter · #4 ·
I have a curtis 1221 controller.... only CAN pull 400 amps, and has never blown anything under load.

I have maybe not switched on/off/on rapidly before, and not just after disconnect from charge while it was pulling 12 amps.

I am curious if it is some weird combination of controller/dc-dc/charger capacitors, or a ground fault in the new charger/dc-dc, or just a freak thing....
 
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