Sound like something is not quite right. These contactors should last
forever, basically.
First, are they getting 12 volts? If they are not getting 12 volts all
the time, then they can not close completely or open just a touch.
Something when the pack sag under load, the DC-DC will cut out due to
low input voltage, and the voltage to the contactors (and othre 12 volt
stuff) will stop working. When the contactor opens up just a touch, the
load on the pack goes away, the DC-DC turns back on, and the contactor
shuts hard again.
Next, do you have a controller precharge relay, and is it working
correctly? If your contactor is simply connecting 350 volts into the
zero volt controller input capacitors, it won't last long at all. It can
sometimes actually weld shut! The precharge circuit first closes a small
relay which connect the pack to the controller with a modest resistance.
Then, when the capacitors build up voltage close to the pack voltage,
the main contactor can then close with a bit less violence.
Two years is a it long, but a contactor might last that long under such
treatment.
Bill D.
On 6/13/2024 4:46 PM, John Lussmyer via EV wrote:
One of the contactors in my truck is failing. It's one of the white
ones (LEV200 I think).
These don't seem to last more than a year or two in my truck.
I run a 350v pack, and limit battery draw to 600A - and rarely pull
that much.
Any suggestions for a more reliable unit?
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