Prelude conversion project - some questions

[jonescg]

I believe it's rated to 450 A and 1000 V DC.

[brunohill]

Looks good Chris. I hope you know which red wire is the positive and which red wire is the negative?

[francisco.shi]

There is some red tape on the positive and black tape on the negative.

[francisco.shi]

I believe it's rated to 450 A and 1000 V DC.

Where did you get the connector from?

[jonescg]

I bought these from Amphenol Australia, but EV-Power has a stash of them too.

[jonescg]

Spent today wiring up the CAN Bus between each of the Zeva modules.
I also made the female plug side of the 18-way connector. Like an idiot I started populating from the back, so it was that much harder to solder. Got there in the end.

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[jonescg]

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Took a little while to work out why it wasn't talking - I had to tell it which channel they were on

I haven't wired the last two modules up yet, but I'm sure they will be fine. What I am unsure of is whether or not the Greatland controller will play nice with the Zeva EVMS. The Zeva unit manages contactors and auxiliary contactors, isolation etc etc, but the controller is pretty dumb. I will have to work out the best way to use the features, and which ones I need to drop.

Ultimately, I want the process of plugging the charger in to close the master (auxiliary) contactor so that things like the DC/DC converter and air conditioning compressor can function. But I don't want the vehicle to be driveable in this state.

[oudevolvo]

Nice progress!
Does the BMS support a three contactor setup?
So:
1. Main +
2. Charger -
3. Main -
Or perhaps two (Main / Charger)?
Then you can have a 'charge' mode where the main + closes and the charger relay and a 'discharge' mode where main + closes and the main - (or the other way around).

[jonescg]

It supports two contactor outputs, main and auxiliary. I believe the difference between them is that the main contactor is also expecting a precharge process, while the auxiliary contactor is primarily for isolation when not in use. However in my case I will have the auxiliary contactor powering everything HV except the inverter, which is powered by its own start-up process, hence I will probably only use the Zeva system for opening the main contactor if a cell goes too low or something.

I took a day of paid leave today to help Daniel get a head start on the adaptor plate. It was a bit frustrating because I had to search for tools whenever i needed one, but also because the flywheel adaptor already mounted on the shaft of the motor was for a BMW and won't match the Honda flywheel. Moreover, it was stuck fast good and proper. No amount of heat, pulling, bashing, or prying was going to get it to budge. We may yet need to cut the bugger off, but damaging the output shaft would be a bad outcome. I really long for a single speed reduction motor-transaxle so this archaic approach is relegated to history.

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The aluminium spacer plate is to give the motor the depth it needs to reach the clutch assembly. A new clutch is due to arrive tomorrow, so I hope we can get a decent flywheel adaptor made.

[brendon_m]

I assume that means you are keeping the clutch.

[jonescg]

Ideally, yes. That is to say, I have spent money on one, so I hope to see it used

[jonescg]

Well while the motor and transmission are on a long date, I have some basic measurements to go on for the rest of the engine bay.
I need to fit the last two battery modules (total weight of 40 kg) as well as an aircon compressor, 12 V power steering unit, water heater, pumps, brake vacuum reservoir, inverter, onboard charger and DC/DC converter. Since the battery is the largest and heaviest item, it probably belongs somewhere towards the firewall and down a bit, since it will have a height of 200 mm or so. Inverter is much the same, so probably also towards the back. How are people mounting this 'shelf' in the engine bay? And are you making an effort to ensure it leaves most things fairly waterproof? I'm envisaging an H frame of sorts spanning anything above the motor, with a sheet of aluminium for splash resistance.