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Ford Fusion Energi Forum

Upgrading the Charger


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The charger in the Fusion is limited to 3.8kw.  I've measured that it puts about 4 amps into the HVB when charging.  Interestingly enough it's no faster if the car's in accessory or full on mode.  Heat can sure hog power though!

 

Has anyone had experience swapping the charger/rectifier module of their Fusion for another Ford model's charger thats rated for a higher wattage? 

 

I'd expect to need to upgrade the conductors between it and the HVB to handle the increased charge current, though maybe not.  I saw amperages as high as 70 when driving!  So maybe a charger two or three times as strong would still be well within the limits of the wiring.

 

Has anyone done this before?

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You do not want to mess with the charger for a LI-Ion battery.  Overcharging a Li-Ion battery releases the smoke and fire.  The charger must be able to continuously reduce the charge current as the max charge point is approached.

 

Hold a beaker in your left hand.  Pour a very strong acid into the beaker.  What is the penalty for pouring too much acid? 

 

The same is true for charging a Li-Ion battery.  The penalty is severe if maximum is exceeded.

 

 

 

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