Prelude conversion project - some questions

Technical discussion on converting internal combustion to electric
antiscab
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Re: Prelude conversion project - some questions

Post by antiscab » Thu, 08 Aug 2019, 10:56

why not just use the display that comes with the ZEVA? it already displays charger data from the CAN bus
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Re: Prelude conversion project - some questions

Post by jonescg » Thu, 08 Aug 2019, 11:22

And convert it into an LED flashing? Just thinking of a way of using the LEDs there, that's all.
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Re: Prelude conversion project - some questions

Post by coulomb » Thu, 08 Aug 2019, 11:58

jonescg wrote:
Thu, 08 Aug 2019, 10:53
TC used to supply a pinout for the LED but this doesn't appear to be the case on the big charger.
I believe that facility disappeared with the 7-pin round connector. My understanding is that the new chargers are potted, and so are not amenable to mods like this would require, but I've not seen inside them.
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Re: Prelude conversion project - some questions

Post by jonescg » Thu, 08 Aug 2019, 12:12

Hmm, sounds like one day a photodiode array detector and signal transformation might be applicable... in a round-about complicated way.
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Re: Prelude conversion project - some questions

Post by jonescg » Sat, 10 Aug 2019, 19:36

Slowly populating the HVDC box. I noticed that there are two kinds of cable gland. Those that use a metric sizing, and some PG thing, which accommodates the same size cable as a 25 mm cable gland, but calls for a 28 mm hole... Serves me right for using what i have lying around instead of buying the right stuff. Water heater contactor is in, as well as the pre-charge relay (I'll be getting a mini-tactor shortly - this one has a 48 V coil, but it's good for size.
HVDC dist box populated.jpg
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I'm slowly going through and making busbars, fixing wires to the fuses and generally trying to fit it all in. I'm always amazed at how much space cable glands call for. I've already exhausted the only available side of the box, and most of this is 50 mm2 power cable from the two battery boxes, and the output to the drive inverter. I still need to fit all the 12 V wiring as well as the CAN lead for the current sensor.
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Re: Prelude conversion project - some questions

Post by jonescg » Sun, 11 Aug 2019, 20:16

Battery cooling loop was primed and circulated for ages trying to get every last air pocket out. I think it will just have to be what it is, and maybe the air pockets will work their way out as the car bumps down the road. SO far so good.
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I picked up a stack of 5/8" hose with 90' bends so I can put the inverter/charger/motor/radiator cooling loop together. Then we are a few late nights away from spinning it up!
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Re: Prelude conversion project - some questions

Post by jonescg » Mon, 12 Aug 2019, 21:54

Battery cooling loop has been bled - I added green corrosion inhibitor as well. The heat exchanger is keyed into the plate and doesn't move.
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I will need to restrict the flow to the front battery modules as they will take the bulk of the flow otherwise. The other frustration is the way the coolant circulates, bubbles don't tend to find their way to the reservoir naturally.
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Re: Prelude conversion project - some questions

Post by jonescg » Wed, 14 Aug 2019, 19:54

With a bit of help from @zeva I think we have a workable solution for the EVMS 3 and Greatland inverter integration.

The Greatland inverter is simply powered on by supplying a switched (Key ON) supply, but the inverter won't be ready to drive until the precharge relay (IGN) is engaged long enough to precharge the caps. At this point the inverter supplied 12 V to the drive contactor which closes and the vehicle is ready to drive. I'm routing the original inverter supply line to the Key pin of the ZEVA EMS3 and taking the Main Contactor output of the EVMS3 to the Greatland inverter, sort of inserting the ZEVA unit in the middle. This way if a cell is low, it will sound the warning, and effectively turn the key off. The high cell voltage situation should be managed entirely by CAN Bus as the TC charger is set up to work well with the BMS.
Charge control box3.png
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And as indicated:
EVMS3 Greatland link.JPG
EVMS3 Greatland link.JPG (98.75 KiB) Viewed 216 times
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Re: Prelude conversion project - some questions

Post by jonescg » Sat, 17 Aug 2019, 16:04

Video progress report for today - power steering and brake vacuum pump are installed. Other stuff... not so much.

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Re: Prelude conversion project - some questions

Post by jonescg » Sat, 17 Aug 2019, 18:10

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Here's the conundrum. If we try to fit everything in as planned, it will be extremely crammed and quite difficult to work on. Also, the heat exchanger and aircon might not fit at all. Moreover, the speedo cable is right in the middle of everything, so if we ditch that we need an ADR approved alternative.

Or we settle for just the 6 battery packs at the rear and live with a 270 volt nominal system. This is just over 18 kWh, which might give 100 km range at metropolitan speeds. If we do this, we can fit all of the gubbins under the bonnet with a bit of room to breathe, and we can use a decent cell cooling system. It also means it can be driven in under a week, rather than ... who knows how long.

Hope to discuss with Francess tomorrow afternoon to get some directive.
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Re: Prelude conversion project - some questions

Post by jonescg » Sun, 18 Aug 2019, 17:32

Well the decision to make it a shorter range, lower voltage car was made. Sad, but I'll feel much better knowing that there's nothing rubbing of chaffing against something it shouldn't.

It will make for a less powerful car too, with peak current around 200 A and 270 V nominal, it's a mere 55 kW machine. But, hopefully we won't be exceeding the original 1100 kg mass so it will go OK. The gears will prove essential up the hill I think.

As I'd already cut and crimped the lugs on the main pack leads before this decision, I had to make a terminal box. Might be a useful spot for a voltmeter or something :)
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Probably worth putting the bonnet back on fairly soon so I can work out what fits where. It's not driving today, but no reason it can't turn a wheel by next weekend.
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Re: Prelude conversion project - some questions

Post by brunohill » Sun, 18 Aug 2019, 21:17

Maybe you need a bonnet scoop. People may think it is supercharged.

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Re: Prelude conversion project - some questions

Post by jonescg » Mon, 19 Aug 2019, 10:54

I can probably find a smaller box for the charge control box - it doesn't need to be this tall.

Bingo!
https://www.altronics.com.au/p/h0312a-r ... enclosure/
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Re: Prelude conversion project - some questions

Post by jonescg » 42 minutes ago

I popped the top off the 6.6 kW TC charger, and yep, it's potted like crazy in there, so no repairs will be happening here I suspect. However I could bolt the DC/DC converter to the lid with ease:
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