Sunday, September 7, 2014

BATTERY PACK CONNECTED

An early start this morning and some real progress was made on connecting the battery pack. All of the connections have been made and once the 12 volt battery cut-out arrives from South Africa, everything can be tested.


NEGATIVE PACK CONNECTION


POSITIVE PACK CONNECTION

The Better Place cell terminals are a bit flimsy so I had to try to support them as good as possible. The positive side bus bar has a nylon bumper added so the force of the lead going to the electrical box that contains the contactor and emergency/maintenance cut out, will be pulling strait down and not pulling at an angle. Once the cables are tightened down, the whole connection should be stiff enough that it will not flex.

Additional spacers were added to the Plexiglas top cover and this morning when I opened the motor cover, it kept the water from the dew that had collected over night from getting to the battery terminals. 

Also the shunt and positive pack voltage wires were run into the cabin of the car, so soon I will be back inside the car getting the wiring ready so the center console can be re-installed and the JLD404 mounted.


NYLON SPACERS ADDED TO PLEXIGLAS


RED AND GREEN TWISTED PAIR FOR SHUNT AND YELLOW POSITIVE  WIRE

The Fiero will be insured soon, hopefully about the same time the car is ready for a test drive with the Better Place Module. The way I set up the connections to the module will make it easy to connect the cables going to the front of the car and I will be able to drive the car while installing the front modules.

Now that I have bottom balanced one of the modules the other two will be easy. I will hook the two 1500 watt halogen lamps and start draining the pack, while checking the voltage on all of the cells. Once the lowest cell is identified, I will set up the JLD404 with a contactor that will shut off the lights when the lowest cell reached 2.5 volts and will turn back on then the lowest cell comes back to 2.7 volts. I will leave this set up for a week, then let the pack set for a week to settle out. Finally,  I will find the highest voltage cell and use the Powerlab 6 to charge all of the cells up to that value. This seems to be the quickest way to bottom balance these cells.

Thanks for visiting,

Randy
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