Do I need a new controller?

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Richo
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Do I need a new controller?

Post by Richo »

Paul9 wrote: How come it worked fine for the last 7 years when wired the same way?


I thought the issue was zapping not a functional problem.
You would have to remember over the last 7 years if you actually touched the a traction pack terminal and exposed chassis.
And it would have to be 72V+ differential to perhaps even to notice it.

So it is plausible you never noticed.


There are plenty of ways to isolate a shunt.
Personally I'd rather isolate the signals rather than the TBS power.
This way the gauge is low voltage.
So the short answer is NO but the long answer is YES.
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Richo
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Do I need a new controller?

Post by Richo »

Paul9 wrote:I use a 5:1 voltage prescaler.

Yeah so even this will cause a leak - not just the shunt.
It wont matter if it's the + or - wire connected to the traction pack.
So the short answer is NO but the long answer is YES.
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Paul9
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Do I need a new controller?

Post by Paul9 »

Thanks guys,

The problem with my understanding is that over the last 7 years I have fiddled around with wiring in the car. Bear in mind the "I" in the sentence above knows nothing about electrical wiring. The chances of me NOT having touched the TRAC pack, and body of the car, simultaneously, at least 20 times, is a million to one. But not one zap!

The people (experts) Johny contacted maintain that the TBS Pro has always connected HV and 12v. Why, after 7 years, have I only, in the last two months got zapped 4 times!

Maybe I just disconnect all the wiring between the TBS and the pre-scaler (and the prescaler and its connections) and re-wire? There is a connector strip between the TBS and the pre-scaler which appears a bit dirty - I better clean that too?

Thanks again people,
Paul
Peter C in Canberra
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Do I need a new controller?

Post by Peter C in Canberra »

I think the TBS pro was designed at a time when traction packs were of sufficiently low voltage that having a link from 12V to traction battery did not introduce a safety risk. For higher voltages such as 120V or 144V you should keep them separate.
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Paul9
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Do I need a new controller?

Post by Paul9 »

Thanks guys - at least I know which area to attack!

Cheers
Paul
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Richo
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Do I need a new controller?

Post by Richo »

Paul9 wrote:The chances of me NOT having touched the TRAC pack, and body of the car, simultaneously, at least 20 times, is a million to one. But not one zap!

Why, after 7 years, have I only, in the last two months got zapped 4 times!


Well as I said you would have to touch the "right" terminal to notice.
Not all terminals will have a sufficient voltage differential to actually zap you.

Add to that your probably doing more pack work recently than in the last 7 years due to replacement/adding cells.

It is possible that there is a fault in the module that will give you a more noticeable zap.

Doesn't really change the outcome.
So the short answer is NO but the long answer is YES.
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Paul9
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Do I need a new controller?

Post by Paul9 »

Thanks Richo, I appreciate the advice (and your previous advices).

Cheers
Paul
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