Hello everybody,
In the last two days, I've noticed two very strange things with my Honda del
Sol. I should explain that it is somewhat taken apart as I finished up some
wiring projects. As I was putting it back together, I noticed two things:
1. While charging with my small charger (Skycharger B6AC RC charger) I'm
getting a voltage on the chassis frame relative to the AC circuit ground. I
noticed this when the trouble light I usually hang from the hood sparked
when I put it back. The trouble light has a metal hood and hook that are
connected to the AC circuit ground. My multimeter says this is about 90V.
If I try to measure current, I get a small spark when the probes touch, but
get no measureable current. During this time, the small charger is
connected to a grounded circuit, but the car is not. This voltage relative
to ground stops when the charger turns off.
2. I'm also getting a measurable voltage between chassis ground and the
Thundersky Li Ion cells. It is about 135V when the pack voltage is 153V.
I'm sure I checked this when I first got the car and had no measurable
voltage between the 12V system and the 150V system. This voltage happens
whether I'm charging or not. I've tried to measure current on this circuit
and also get sparks, but no measurable current. The leak is fairly rapid as
I get enough charge to cause another spark in a few seconds.
The current state of the car while this situation is happening is a little
strange. I've removed all the new wiring I installed. Also, the manual
disconnect before the main contactor is open. The main contactor is also
open since the ignition is off. Finally, the B+ connection to the
controller is not connected. That shouldn't matter since the manual
disconnect is also open. The M connection to the controller is also not
connected. These unconnected cables are well insulated from the frame
(sitting in their rubber covers and not touching metal).
The B- connection to the controller is connected. The pack connection to
the charger, DC controller, etc. were all removed when I removed my new
wiring box. The controller is a Kelly KDHD. The main charger is an Elcon,
but I don't think that is implicated because it is completely disconnected
(both AC inputs and DC outputs).
The positive and negative battery connections are only the high-current
cables and a low-current cable (one to most positive cell and one to the B-
on the controller) going to my new wiring. Since that box is removed, these
are currently sitting as open circuit Anderson PowerPak connectors.
For normal charging, this shouldn't be an issue because I'll have the AC
circuit ground attached to chassis ground, but I would really like to
understand why I have leakage causing my chassis ground to float along with
the batteries. It's also causing strange behavior when I start charging
with the small charger and I think it could easily damage something.
I can only think of 3 causes of this:
- The controller is doing something and backfeeding high-voltage onto the
chassis ground. It doesn't seem like it should be doing that!
- A cable has lightly shorted to the frame somewhere. In general, the
cables are well protected and shouldn't be rubbing. There is one spot as
the cables go into the trunk to the second bank of batteries that I have to
check.
- Something is causing the cells to conduct electricity to their mounting
brackets and then the frame.
Does any of this make sense? Does anyone have any hints about how to look
into this further? I plan to disconnect the B- connection to the controller
as soon as the Skycharger is finished. Anything else to try?
I'm grateful for any hints or suggestions you can provide.
Mike
_______________________________________________
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In the last two days, I've noticed two very strange things with my Honda del
Sol. I should explain that it is somewhat taken apart as I finished up some
wiring projects. As I was putting it back together, I noticed two things:
1. While charging with my small charger (Skycharger B6AC RC charger) I'm
getting a voltage on the chassis frame relative to the AC circuit ground. I
noticed this when the trouble light I usually hang from the hood sparked
when I put it back. The trouble light has a metal hood and hook that are
connected to the AC circuit ground. My multimeter says this is about 90V.
If I try to measure current, I get a small spark when the probes touch, but
get no measureable current. During this time, the small charger is
connected to a grounded circuit, but the car is not. This voltage relative
to ground stops when the charger turns off.
2. I'm also getting a measurable voltage between chassis ground and the
Thundersky Li Ion cells. It is about 135V when the pack voltage is 153V.
I'm sure I checked this when I first got the car and had no measurable
voltage between the 12V system and the 150V system. This voltage happens
whether I'm charging or not. I've tried to measure current on this circuit
and also get sparks, but no measurable current. The leak is fairly rapid as
I get enough charge to cause another spark in a few seconds.
The current state of the car while this situation is happening is a little
strange. I've removed all the new wiring I installed. Also, the manual
disconnect before the main contactor is open. The main contactor is also
open since the ignition is off. Finally, the B+ connection to the
controller is not connected. That shouldn't matter since the manual
disconnect is also open. The M connection to the controller is also not
connected. These unconnected cables are well insulated from the frame
(sitting in their rubber covers and not touching metal).
The B- connection to the controller is connected. The pack connection to
the charger, DC controller, etc. were all removed when I removed my new
wiring box. The controller is a Kelly KDHD. The main charger is an Elcon,
but I don't think that is implicated because it is completely disconnected
(both AC inputs and DC outputs).
The positive and negative battery connections are only the high-current
cables and a low-current cable (one to most positive cell and one to the B-
on the controller) going to my new wiring. Since that box is removed, these
are currently sitting as open circuit Anderson PowerPak connectors.
For normal charging, this shouldn't be an issue because I'll have the AC
circuit ground attached to chassis ground, but I would really like to
understand why I have leakage causing my chassis ground to float along with
the batteries. It's also causing strange behavior when I start charging
with the small charger and I think it could easily damage something.
I can only think of 3 causes of this:
- The controller is doing something and backfeeding high-voltage onto the
chassis ground. It doesn't seem like it should be doing that!
- A cable has lightly shorted to the frame somewhere. In general, the
cables are well protected and shouldn't be rubbing. There is one spot as
the cables go into the trunk to the second bank of batteries that I have to
check.
- Something is causing the cells to conduct electricity to their mounting
brackets and then the frame.
Does any of this make sense? Does anyone have any hints about how to look
into this further? I plan to disconnect the B- connection to the controller
as soon as the Skycharger is finished. Anything else to try?
I'm grateful for any hints or suggestions you can provide.
Mike
_______________________________________________
| REPLYING: address your message to [email protected] only.
| Multiple-address or CCed messages may be rejected.
| UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub
| OTHER HELP: http://evdl.org/help/
| OPTIONS: http://lists.sjsu.edu/mailman/listinfo/ev
