I got stranded because a fuse blew in my battery box that effectively
disconnected the DC to my charger. My EV is a US Electricar S10 pickup with
3 phase AC controller. System voltage ~320VDC.
I have a contactor in the battery box that supplies pack voltage to the
Manzanita PFC40 charger, a 3kW resistance water heater and a Masterflux BLDC
A/C compressor controller. Each of the 3 units have their own separate fuse
built in.
The line is fused before the contactor by an A50QS60 500VDC 60A
semiconductor fuse. The fuse never sees more than 30A continuous, usually
much less. The only downside to this arraingment is that the charger and
BLDC controller always have pack voltage on them when driving or charging.
The fuse has been in service for about 2 years. Could the capacitor inrush
current of the charger and BLDC controller, every time the contactor
energizes to drive or charge, have caused the fuse to gradually fail?
Wouldn't the "local" lower value fuses have blown first? I don't think the
Manzanita chargers have a lot of capacitance on the output and the BLDC
controller has a few fairly small electrolytics on the input.
What say the group?
Thanks, Al
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