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Warp 9 shorted

3298 Views 9 Replies 5 Participants Last post by  dimitri

Just a quicky for anyone interested. I had a shorted Warp 9. It caused a Curtis controller to fry, and my Manzanita to also fry. Thought it was my battery pack, and it may have been shorted to frame from salt spray, but once the motor got shorted enough, it started frying things.

Anyways, once I found the short on the field coils to the frame and pulled the motor, it was surprisingly easy to tear the thing apart and remove the rotor. Cleaned the case and coils, but the short was still there, so carefully removing the bolts for the field coils, and numbering them so I got everything back in correctly, I pulled the coils and found one with that tape stuff off to one side, and the short / burn through right at that point. Cleaned, re-taped and threw it back together. Short gone! Actually the short went away when I unbolted the third field coil, bolted it back in right away and the short came right back.

It was amazing how easy it was to put back together. Pulled the brushes almost all the way out so the springs would hold them out of the way when putting the rotor back in.
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Sorry to hear you went thru all that trouble.

One piece of advice , isolate that damn charger from the chassis. Mount it on rubber standoffs, or use nylon bolts, etc. Do not let charger's case contact your chassis. This is primary reason why you keep blowing your BMS boards. Obviously its not related to motor shorting, but it keeps adding up to your troubles.

Manzanita connects its case, which is connected to AC neutral, to your 12V ground ( chassis ), which removes isolation between high and low voltage circuits. Without such isolation, any other conductive path ( salt, wire short, etc ) completes the circuit and blows stuff up.

Oh, and don't work on the car while charging and disconnect the pack from everything else when working on BMS connections.

BTW, since I sympathize with your troubles, I'd like to offer free repair of your BMS boards, you'd just pay for shipping. Send me all failed boards and I will fix them for you.
I will go check for sure!

I have been under the hood a LOT lately with charger running as I was measuring cell voltages during the balancing process. So, I am either really lucky, or the Elcons are isolated. ;)
Elcons ARE in fact isolated, so you are OK there.
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