Tuesday, August 27, 2013


This week I decided to test the charging relay and when I applied power, nothing happened. I checked the 12 volt battery and it was under 1 volt. After looking around the car I found the drivers side door was ajar and the interior lights had run the battery down. I hooked up the DC-DC converter to AC and let it charge until the voltage came up to 13.2 volts then disconnected the charger. When opening the drivers side door, the interior lights came on and the battery was still holding above 13 volts. It is good to know my bottom balance on the Ballistic battery worked and there did not appear to be any damage but may still install a timer circuit to take out the interior lights after a couple minutes, to prevent this from happening again. The battery is only 2.3 A/h but I only intended to have it power up the J1772 circuit and turn on the DC-DC converter when charging. I ran the lead acid batteries down a couple times when I forgot to unplug the DC-DC converter and wanted to have a way to shut it down when the ignition switch is turned to off.

The engine compartment is done and I am preparing to install the motor cradle. There will still be a few wires to run and some loom to install but I need to wait until the motor is in to decide on the routing.


The controller will need to be removed from the motor to get clearance for the cradle to go back in and some wires will need to be tied up out of the way to keep from damaging them. The speedometer plug was pulled off when I dropped the cradle but thanks to EBAY, another one is on the way.


Only two batteries left to bottom balance and the pack will be ready for the initial charge. Out of the forty, four of them will not hold a charge, so that will leave me with 36 cells. None of them took more that 80 A/H and some of them only took 60 A/H. At 3.65 volts per cell, I will need to have the charger cut off at 130 volts or so but the charger is currently going to 156 volts and then doing a constant voltage stage. I changed the setting on the Zivan to "7", that is supposed to be for lithium but I will need to closely monitor the first charge.  There are a couple adjustments inside the charger for voltage and current so I am hoping the voltage can be turned down far enough using them. I have a chip for the Zivan that allows it to be programmed with a PIC3, so eventually, I want to install it so I will have a little better control of the charger. The Synkromotive Controller also has a charge function but there is no documentation on how to hook it up. There are settings in the set-up program but I am not sure anyone has tried to hook it up to AC using an inverter. If anyone has hooked the Synkromotive Controller up as a charger, leave a post and let me know how it worked out.

Thanks for viewing,


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