This weekend was all about cables. I mounted the DC/DC on the front battery box and connected it to the hight voltage in the front connection box, the engine room earth point, and the 12V "intake" in the left footwell under the driver's feet.
The DC/DC mounted on the front battery box with the orange high voltage cable
Originally, the 12V battery was placed in the rear of the car and two long cables ran to the front. One 50 mm2 cable to the starter and one thinner, 25 mm2 for the main power supply of the car. I ripped out those cables and joined them together. The starter end of the cable connects to the DC/DC so this way I get 12V for all the systems. Left to do is to connect a 12V battery to the DC/DC.
The two thick plus cables ripped out to be joined
Reducing the 50 mm2 cable to 25 mm2...
... in order to join it with the thinner with a crimp join. Add three layers of heat shrink and some electric tape
I also finished the middle connection box that goes in the right footwell and contains the main 400A fuse, the current shunt for measuring battery current (discharge and charge), and the Tyco contactor that turns on the high voltage.
The middle connection box under the passengers feet
The connections go to the JLD 404 to measure current and voltage, and to the charger to provide unbroken (by the Tyco) minus.
More orange tubes under the car...
... and the front connection box is filling up. |
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The front connection box is getting more and more complete. Left to connect are the hight voltage cables to the motor controller and the charger cable. I ran out of battery cable (a shielded, orange 35 mm2 cable) so I have ordered more from evpower.eu along with a charge intake and connector that conforms to the European standard IEC62196-2. Hope to get it next week.
Hi
ReplyDeleteVery nice car but I wonder why You install fan cooled electronix in front of car they are going get wet? Also cars with small and ecomic diesel engines use diesel heaters Webasto Ardic etc. and still are quit cold at nordic winter 3-4kW electric heater is not enought for winter months. Sincerely Sami
ps. Is'n there some kind of space at trunk behind battery boxes can't You put charger and DC/DC converter there?
Hi Sami,
ReplyDeleteI agree it is not ideal to install these components in the front of the car. I do it because I am worried that installing them in the trunk would make them overheat since there is no ventilation there.
I will try to seal the front as much as possible to reduce the amount of water splash that comes in, and maybe I have to change to a sealed DC/DC. The charger is IP54 so it should be able to take some water splashes.
It will be interesting to see if the 4kW heater is sufficient for the nordic winter. If not there is a 6kW heater element that will fit into the heater cylinder and the electronics (SSRs) are dimensioned to handle that load.
/ Peter
Hi, Is there any update on how this has been going?
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