[zepol_wube]

Our project to convert a 2003 VW Golf to electric using parts from the DOA Ford Azure project and a Nissan Leaf is getting closer to rolling. I am looking for suggestions on rear pack wiring patterns. Please see my blog for the details including pictures and limitations.

 

[zepol_wube]

This pattern looks like the best suggested option. It will allow the sections deeper in the box to be pre-connected leaving only one connection to make near the top of the box between the 6 pack and the left 10 pack. This arrangement requires 13 long bus bar connections. The original leaf pack only had 10. So we are short 3. It is simple enough to make the bus bars, but we would also like to reuse the Leaf orange safety housings like we did on the front boxes. Anyone in the U.S. have some spare leaf protective covers we may use?

 

[galderdi]

Looks ok but am I missing something?

Why wouldn't you spin the lower left pack clockwise 90 degrees and the lower right pack anti-clockwise 90 degrees to minimise some of the cable cross over and potentially reduce the amount of cable required?

 

[zsnemeth]

I'd say swing them around 180 degrees, that is the shortest cable route and even less crossover and it is the same size and form factor.

 

[zepol_wube]

Space constraints, modules side by side are 19" wide, individual modules are only 11.5" long.

 

[zepol_wube]

180 was an option which would decrease the length of the one long connection, but then increase the length of the upper connection as the outgoing connection is from the middle. It would also place the upper two connections in hard to reach corners.

 

[zepol_wube]

Started building it, please consider thread closed.

Thank you

 

[zsnemeth]

Started building it, please consider thread closed.

Why?????

You know, the whole point of the forums is, that people ask questions, because they want to here other peoples opinion. Right?
Than, they get answers, sometimes just one, sometimes a lot more.
Than, the OP can decide will He take them or leave them. Right?
When the OP finished his build/problem solving/whatever, He documents it in the thread and tells his experiences, sometimes even the test data about it.
Than, a couple of few month usage later he's coming back and tells how it's worked out....

This way people CAN learn from the forum, and not asking the same damn questions over and over again.

 

[zepol_wube]

Sorry, newbie error?

I came, I got answers and suggestions, I settled on one of the suggestions and posted the direction I have chosen to go, I do not want to have folks waste their time on a custom configuration that has been solved when there are other questions that they could be answering to help me or the next person.

My next issue is finding a DC-DC converter. I would rather you apply your knowledge here than read an old post that I have moved on with shared information. Thank you for the forum etiquette lesson, I will not "close threads" in the future.

 

[WolfTronix]

Would this work:
http://www.diyelectriccar.com/forums/showthread.php?t=181490

Or do the power terminals end up in bad spots?

 

[zepol_wube]

Would this work:
http://www.diyelectriccar.com/forums/showthread.php?t=181490

Or do the power terminals end up in bad spots?

I stared at yours a lot while thinking about patterns. Space constraints made me shy away from duplicating it. I do not think I can get the posts in at all in the 90 degree configuration you show, I believe I will need to make my connections parallel to the pack face. My assembly process is currently to install the 6 rear modules, wire/bus-bar/sensor connector them together with their two long wire leads attached. One of the leads for the + will have the main relay already on it. Wire/bus-bar/sensor connector the two packs of 10 with the long cable and the main lead wires between the packs installed. Lower the 6 pack and shell over the 20 pack and connect the 6 pack to the top of the 20 pack just before it goes all the way in. Secure everything to the shell. Flip it all upside-down. Reach in between the 10 packs and secure the main relay then make the two main connections to the external main connector. One of the connections is - neg and the other is + but after the relay so "dead". I had also considered placing a temporary frame on the top of the 20 pack to hoist it into the shell, but I am more concerned with stressing the bus-bar connections and lifting the 200# of batteries than flipping it over after the batteries are secured to the shell. I have a hoist...
I know you were using fewer modules that 48. Did you end up with 3 extra long bus-bars and associated leaf orange housing we could use?

 

[WolfTronix]

I do have some of the long bus bars left over, but I think I will hold on to them... I have plans for the left over modules and interconnects.

You could go in a more serpentine pattern, and reduce the need for the long bus bars.

 

[zepol_wube]

Got it, I think... pack need not be symmetric.

Needs fewer long bus-bars, now to see if I can get the safety plastic to conform.