THJ Media Blog

2019-03-24_e-Stang_charger_testing Posted on March 24, 2019 14:57:37.

Mustang 240V charging with dead fans
3/24/2019

Charger fans died second time. First was Papst IPC 1154 rated that only lasted 3 years, required charging at 7.5 amps on warm days because it would not cut back agressively enough and would cut off.

Second ones were Delta IPC 1155s that lasted 9.5 years.

Without fans in 56 degree weather inside the garage, after 10 minutes at max 20 battery amps or 8 MPH charge rate it got above 100C and throttled to 16 amps at 107C, 6.4 MPH.

Put a ~18" fan pointed down in the engine compartment and the temperature dropped to 105C and increased to 18A, 7.2 MPH. This might be an acceptable workaround if 120V is also available but it usually isn't. I might try powering the fan on the inverter.

Throttled to 14A or 5.6 MPH and it went to 100C, so the max recommended at 56F. This is pretty linear though so I thought I'd go down in current and see where the temperature stabilized.

12A gave 94C, 4.8 MPH
10A gave 82C, 4.0 MPH
8A gave 74C, 3.2 MPH
6A gave 64C, 2.4 MPH
120V charges at 5A or 2.0 MPH so probably below this.

So assuming linear shift:

56F ambient 14A max 5.6 MPH 70%
68F 12A 4.8 60%
90F 10A 4.0 50%
106F 8A 3.2 40%
It hasn't ever gotten hotter than this.
126F 6A 2.4 30%