electrical

DC/DC converter troubleshooting

Submitted by Pedro on Sun, 2021-07-25

I'm taking a lot longer than expected to wire my DC DC converter and, worse of all, I'm not having any success. I'm using a TDC-IY-108-12 from a Chinese company named TC Charger (the website www.tccharger.com printed in the manual doesn't exist). I think there are similar converters branded as Elcon. It's a 1kW unit with a nominal DC input of 108V (range can vary from 72V to 162V). Do you have any suggestions?

DC/DC converter arrived

Submitted by Pedro on Thu, 2021-06-17

It's been a while since the last update. I've been busy with other non-related stuff and also some boring stuff, namely wiring the leads for all the battery modules (to connect a manual charger/voltmeter) and a future BMS. At the same time, the DC/DC converter finally arrived, along with some more HV cable and fuses. I've gone for a chinese TCCharger unit good for 1.2kW. I've read mixed reviews about these chinese solutions but the truth is that there is not many alternatives.

High voltage cabling

Submitted by Pedro on Sat, 2020-12-05

Today I was trying out my new tool: pneumatic crimper. And heat gun and super size heat shrink :) I started with the three equal length high voltage cables for connecting the motor and controller.

Wiring diagram

Submitted by Pedro on Fri, 2020-03-06

The electric motor controller needs to tap on the "ignition" signal, so that it turns on when the key switch is turned into that position. I immediately noticed that the "acc" position of the key switch is not working as it should. The "acc" is suppose to power the radio and cigarette lighter only, just before the next position, "ignition". But the key switch or its wiring must have been messed up with since the "acc" does not exist. The "ignition" is always on with the switch either in "acc" or "ignition". So, I started looking closely at the wiring to see what else was not stock.