1. Introduction
This manual provides essential information for the safe and efficient operation, installation, and maintenance of the Elcon TC Charger HK-MF-144-23. This high-efficiency, power factor controlled on-board battery charger is designed for electric vehicle applications, offering robust performance with an IP67 protection rating.
Video: 360-degree view of the Elcon TC Charger HK-MF-144-23.
2. Specifications
2.1 Basic Specifications
| Feature | Specification |
|---|---|
| Input Voltage Range | AC 90V~264V |
| Input Current | 16A |
| Frequency | 45Hz~65Hz |
| Power Factor | ≥0.99 |
| Efficiency at Full-Loading | ≥93% |
| Protection Grade | IP67 |
| Operation Temperature | -40°C ~ 85°C |
| Storage Temperature | -40°C ~ 105°C |
| Charging Control | CAN or Enable |
| Size (Fan-cooled) | 198(L) x 244(W) x 95(H) mm |
| Protection Features | Output over-voltage, over-current, short-circuit, polarity reverse, input low-voltage, input over-voltage, over-temperature |
| Cooling Way | Enforced Air Cooling, Liquid-cooling (model dependent) |
| Mechanical Impact and Vibration Grade | QC/T 895-2011 |
2.2 Model Specific Parameters (OBC 3.3KW)
| Model | Cooling Type | Output Voltage | Output Voltage Range | Output Current | Output Power | Net Weight (kg) | Gross Weight (kg) | Dimension (CM) |
|---|---|---|---|---|---|---|---|---|
| HK-MF-48-40 | Enforced Air Cooling | 48V | 35~70V | 40A | 2000W@220VAC / 1600W@110VAC | 4.6 | 5.6 | 36*32*20.5 |
| HK-MF-108-32 | Enforced Air Cooling | 108V | 36~145V | 32A | 3300W@220VAC / 1600W@110VAC | 4.6 | 5.6 | 36*32*20.5 |
| HK-MF-144-23 | Enforced Air Cooling | 144V | 50~198V | 23A | 3300W@220VAC / 1600W@110VAC | 4.6 | 5.6 | 36*32*20.5 |
| HK-MF-216-14 | Enforced Air Cooling | 216V | 70~290V | 14A | 3300W@220VAC / 1600W@110VAC | 4.6 | 5.6 | 36*32*20.5 |
| HK-MF-312-10 | Enforced Air Cooling | 312V | 110~440V | 10A | 3300W@220VAC / 1600W@110VAC | 4.6 | 5.6 | 36*32*20.5 |
| HK-MF-540-06 | Enforced Air Cooling | 540V | 170~650V | 6A | 3300W@220VAC / 1600W@110VAC | 4.6 | 5.6 | 36*32*20.5 |
2.3 Dimensions
Figure: Detailed dimensions of the charger unit.
3. Setup and Installation
Proper installation is crucial for the charger's performance and longevity. Ensure the mounting location provides adequate ventilation and adheres to the specified clearance requirements.
3.1 Mounting Orientation
The charger should be mounted in an orientation that allows for optimal heat dissipation. Refer to the diagram below for recommended and forbidden mounting positions.
Figure: Recommended and forbidden installation methods. Ensure at least 50mm distance off any obstacle.
3.2 Electrical Connections
The charger requires specific electrical connections for input power and output to the battery. Use the appropriate connectors and terminals provided or recommended by the manufacturer. Ensure all connections are secure and properly insulated.
Figure: Air Cooling Accessories (connectors, terminals, and housings). Matching accessories may vary by production batch.
Important: Always disconnect power before making or breaking any electrical connections. Consult a qualified electrician or automotive technician for complex installations.
4. Operating Instructions
The Elcon TC Charger HK-MF-144-23 is designed for automatic operation once properly installed and connected. It features CAN or Enable charging control.
- Connect to Power: Ensure the charger's AC input is connected to a compatible power source (AC 90V~264V, 45Hz~65Hz).
- Connect to Battery: Ensure the charger's DC output is correctly connected to the vehicle's battery pack. Observe correct polarity.
- Initiate Charging: Charging can be initiated via CAN communication or an Enable signal, depending on the vehicle's system integration. Refer to your vehicle's specific wiring and control documentation.
- Monitor Charging: The charger will automatically manage the charging process. Monitor the battery status through your vehicle's display or battery management system (BMS).
- Completion: The charger will automatically stop charging when the battery is full or if an error occurs.
5. Maintenance
The Elcon TC Charger HK-MF-144-23 is designed for minimal maintenance due to its robust IP67 rating. However, regular checks can ensure optimal performance and longevity.
- Visual Inspection: Periodically inspect the charger for any signs of physical damage, loose connections, or corrosion.
- Cleanliness: Keep the charger's exterior, especially the cooling fins and fan (if air-cooled), free from dust, dirt, and debris to ensure efficient heat dissipation. Use a soft, dry cloth for cleaning.
- Connection Integrity: Ensure all electrical connections remain tight and secure.
- Ventilation: Verify that the area around the charger maintains the recommended 50mm clearance for proper airflow.
Do not attempt to open or repair the charger yourself. Refer all servicing to qualified personnel.
6. Troubleshooting
If the charger is not functioning as expected, perform the following basic checks before contacting support:
- No Power:
- Check the input power source and cable connections.
- Ensure the AC supply voltage is within the specified range (90V~264V).
- Not Charging:
- Verify that the DC output connections to the battery are correct and secure.
- Confirm that the CAN communication or Enable signal is correctly configured and active.
- Check the battery management system (BMS) for any fault codes or conditions preventing charging.
- Overheating:
- Ensure adequate ventilation around the charger and that the cooling fan (if present) is not obstructed.
- Clean any dust or debris from the cooling fins.
- Error Indicators: If the charger has diagnostic LEDs or communicates error codes via CAN, consult your vehicle's documentation for interpretation.
If the issue persists after these checks, contact customer support.
7. User Tips
- Optimal Placement: When installing, prioritize locations that are easily accessible for inspection and cleaning, but also protected from direct impact or excessive vibration.
- Cable Management: Use proper cable management to prevent strain on connectors and ensure cables are not chafing against sharp edges.
- System Compatibility: Always ensure the charger's voltage and current specifications are compatible with your battery pack and vehicle's electrical system.
8. Warranty and Support
For technical assistance, warranty claims, or any other inquiries, please contact our customer service:
- WhatsApp: +86 15216425580
- Email: congandy02@163.com
Please have your product model number (HK-MF-144-23) and any relevant purchase information ready when contacting support.
8.1 Certifications
Figure: CE Certification for Elcon TC Charger products.