After doing a bad job on the 35-pin ampseal connector to the motor controller, I couldn't get it to start. So undid everything and recrimped it. Three hours of my time gone, hopefully painful enough to remind me to do it right the first time.
No power steering or vacuum assist on the brakes yet so my yard test was straight back and forward again - but it moves!
1. covering up and fixing cables.
2. making a proper lid for the battery box ...
Posted 12-09-2013 at 06:30 AM bysabahtom Updated 12-09-2013 at 06:33 AM bysabahtom
Since everything seems to work, I've pulled the cables through the dash and fixed the PB6 pot box to the chassis, with a backup spring. A failed return spring seems to be the only major fault that AC systems can have that would launch me through a red light.
Still looking on ebay for an appropriate Vicor megapac. Lots to choose from but only a few with 12-12.5v modules. I'd like to get one that will accomodate DC aircon, power steering and vacuum pump for $200. Could take a...
DMOC and CCShell work ok with HV and a stable 12v supply. I'm using the lead acid battery from another car.
Had to disable the CHARGED_ERROR fault, but it seems to persist even though the DMOC is presently resting on a bare metal frame and has a the spec grounding strap fitted. The manual says this error/parameter were removed in later versions so I guess it was too annoying to try to get it right, even in the factory.
I was very cautious with this because my experience tells me that I can ask every question I can think of but there is still room for the thing I wish I'd known. Even so I may have probably done something unnecessary or wrong - but it seems to work, so I'll put all the parts in the car.
1. Connected the traction cables and charger cables to the bus bar and enclosed it in an electrical box. Connected traction fuse, in separate electrical box near the pack. The fuse is on the most negative...
Despite the cost of the thing, my experience of two small shorts while wiring up the pack - 7.2v only - has scared me sufficiently that I don't want any unfused cabling where it could possibly short out the pack.
At the same time, fusing 100 cells would take days and my usage is likely to be only 30% of real pack capacity, so I can probably stay away from both ends. Anybody want to buy an unused BMS?