Monday, February 15, 2016

Tidying Up a Bit

I like to keep things neat and organized, but to a certain extent, things got out of hand with this build. For one thing, it's rather more complex than the last two projects with Siemens AC power and the supporting DMOC inverter and GEVCU controller. The electric air conditioning compressor and its plumbing are a challenge yet to be addressed. The OEM charger and DC/DC converter also have their own controllers, leading to an upcoming consolidation project. Then there is the spaghetti monster in the wiring box.

To disguise that mess, a cover was constructed with 1/4" plywood skin over a 5/8" marine plywood core that was clearanced to allow for the height of the wiring bundles coming from the harness. A little black spray paint makes it disappear, and it's secured with a velcro strap. Not only does it clean up the appearance, it also protects the wiring and terminal blocks from accidental shorts. The GEVCU has been relocated  to the top of the DMOC, held in place by two inch wide industrial strength velcro. I had to unplug the connector to add a terminating resistor, and simply didn't have enough room or leverage to plug it back in where it was previously installed on the back of the DMOC. There's a surprising amount of hood clearance, so it works well and certainly is more accessible.

Here's the view from the other side:

I'm not entirely happy with the GEVCU cable, but it's a dark color and could be worse. 

On the other side, I plan to enclose the contactor and precharge circuits as well now that I think I have that sorted out. With Spring in the air here in Texas, I think it will be time soon to have the air conditioning system charged and get that working before the summer heat sets in.

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