During the course of dismantling jay's charger i discovered that the 'clear' plastic sleeving and black heat shrink tubing on the inductor and transformer wiring had somewhat melted and fused together. i don't know at what temperature that would occur, but it is likely greater than 360 F. i've neve...

seismic seems to have left. Bummer. Anyway, I'm dropping the car off at the mechanic on monday and he will give me a quote / fix it if its not too costly. I will let you know how it plays out. Thanks for keeping us in the loop. It's valuable information that should get recorded for others who run i...

JoeS wrote:BMU case (sits on top of Charger): 95°F (35°C)

Do you have a picture of the charger setup in the 2012? It sounds different than the 2014.

Aerowhatt

There must be much more heat generated when driving the car, cooling the motor and the inverter - I can't believe the cooling system that handles that cannot handle the charger alone. In your tests, do you think you were moving as much air through the radiator as the stock cooling fan would? If the...

There is an OEM fan on the radiator at the front of the car - Any thoughts on just making a mod to use that fan? Many ICE cars have 12 volt cooling fans behind the radiator which are energized using a thermal switch on the radiator tank - When it gets hot enough, the fan comes on for long enough to...

Aerowhatt, what did you pick up as your fan's 12v power source, activated only during charging? Right now it is temporary, separate 12 ah AGM. The DC to DC output is right there and easy to connect to. The negative will go to ground (likely to the bracket for the blower). Fuse (3 amp) right at the ...

I don't think it's been proven, yet, that there are thermal issues -- only that greater cooling is possible. But, what matters is what temperatures are in spec for the components, not whether they're hot to the human touch. I've been charging EV's for clients for 18 years. Recommending and installi...

I have a prototype cooling blower mounted in my car and two charges monitored with it. First let's review. First all of, the numbers are are based on my 80F ambient charging environment. It is reasonable to use these numbers adding or subtracting as needed depending on your ambient charging location...

Is it possible that the resistors were damaged by overheating or is it possible to tell if overcurrent was the cause as he said? Yes over current is caused by over voltage with a resistor (or less common, resistance value drifting out of spec). Over current results in overheating which damages the ...

For completeness I went back and compared E mode and B mode on the same stretch of road. Take note that this was a different day and conditions were different than the conditions in the graphics in the previous post. In the previous post there was a pretty decent headwind. In the following results t...