The output fuse on my PFC30 appears to be occasionally blowing while I am
driving.    The car completes its charge cycle ok, and can top up the pack
if the car has not been used after charging, so I know it's ok before
driving.

If it is driven with motor & battery currents limited to 400A or 500A, there
is usually no problem.   If the current limits are increased to 700A or
more, and that current is used during the drive, then the charger output
fuse *might* be blown when I next try to charge.

One time I heard the fuse pop when starting to turn up the charger current,
so the fuse was not blown until charge time.

I have also checked the fuse after a drive but before plugging in the
charger, and have found it to be blown.

At first I thought that maybe there is a HV isolation fault between the
traction pack and the car frame.  A voltmeter from chassis to voltage points
in the pack shows HV DC, but the voltage quickly drops to zero (well under a
minute).   I presume that this is a capacitive charge that discharges
through the voltmeter.    Is this behavior expected or does it indicate a
problem?

The traction pack has six 40V batteries, and is connected directly to the
charger, motor controller, and DC/DC.  Should I use a diode between the
traction pack and the charger?   Or a inrush current limiter?

Looking for suggestions on how to determine the source of the blown fuse
problem.

Thanks,

Wayne Krauth
evalbum.com/3567



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