tag:blogger.com,1999:blog-77042977223158147602024-02-07T18:53:17.436-08:00PorschEVFred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.comBlogger54125tag:blogger.com,1999:blog-7704297722315814760.post-20093114953198644912016-05-29T12:57:00.002-07:002016-05-29T13:00:12.191-07:00Adventures in EV Land<span style="font-family: "trebuchet ms" , sans-serif;">I've consolidated this project blog with my <a href="http://evtd.blogspot.com/" target="_blank">evTD</a> and <a href="https://sites.google.com/site/fredbehningsebugeye/" target="_blank">eBugeye</a> pages so there is one point of reference for all of the family EV's, including the commercial ones, from now on. The old pages will stay for reference, but new activity for everything will be posted to:</span><br />
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<a href="http://adventuresinevland.blogspot.com/" target="_blank"><span style="font-family: "trebuchet ms" , sans-serif;">Adventures in EV Land</span></a></h2>
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<span style="font-family: "trebuchet ms" , sans-serif;">Thanks for your interest!</span></div>
Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0tag:blogger.com,1999:blog-7704297722315814760.post-20422645906519271812016-04-19T13:44:00.002-07:002016-04-25T07:32:52.898-07:00Berthing Arrangements<span style="font-family: "trebuchet ms" , sans-serif;">Now that the <a href="http://evtd.blogspot.com/2016/04/turning-over-new-leaf.html" target="_blank">new Leaf</a> has come home, it was pretty clear the time had come to rearrange the garage for best utilization. The Porsche EV project is nearing the phase-out stage where it doesn't need a full side of the garage any more. A threatening weather forecast with the possibility of two inch hail pushed the garage to the top of the priority list.</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhT04R2A5IjwTQIwqsFIqNOiBaXC10dFxs9o5uIxk6lio3PNr5sHys52rrxu4e0dqRX_c3MM49k1fk48wTuWL6gOTw2hYRombeMKG_Nkh06aYBjY3Aj4XjyCqPSMEQkBs32tdQkIppW07Q/s1600/IMG_4906.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhT04R2A5IjwTQIwqsFIqNOiBaXC10dFxs9o5uIxk6lio3PNr5sHys52rrxu4e0dqRX_c3MM49k1fk48wTuWL6gOTw2hYRombeMKG_Nkh06aYBjY3Aj4XjyCqPSMEQkBs32tdQkIppW07Q/s400/IMG_4906.jpg" width="400" /></a></div>
<span style="font-family: "trebuchet ms" , sans-serif;">There had to be a way to get all three EVs in this one space and I tried more than a few things that were either unworkable or marginally dangerous until this bit of out-of-box thinking struck. What says the cars must park straight? If the evTD is angled into the nook at the front of the garage, the Porsche and Leaf can be slightly splayed to the outside and Voila! Room to spare!</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif;">Of course there needed to be some serious rearranging of the crud that tends to accumulate in a garage just so you can do things like open the door after you park. After three EV conversion projects there are scraps and odds and ends that need to be either stored away or pitched, likewise with a twenty year accumulation of Flute teaching material (mostly untouched for the last ten years) and antique computer projects. That's on the todo list for another day, but right now I'm pleased to see the three safely under cover.</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpnfMddeG67TFMyC9biDx4Arg1J_vNJeE4PtEsDm7zCQXGuedwJqel_gEEtEZYClKb-E-ZMHFywQSeHotZzCMOHPuaWPYNvaCdlKXAbiMJkdnVF3SZiIbTa00KCs1kyOVqa2WdJ9A6OGY/s1600/IMG_4907.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpnfMddeG67TFMyC9biDx4Arg1J_vNJeE4PtEsDm7zCQXGuedwJqel_gEEtEZYClKb-E-ZMHFywQSeHotZzCMOHPuaWPYNvaCdlKXAbiMJkdnVF3SZiIbTa00KCs1kyOVqa2WdJ9A6OGY/s640/IMG_4907.jpg" width="640" /></a></div>
<span style="font-family: "trebuchet ms" , sans-serif;"><br /></span><span style="font-family: "trebuchet ms" , sans-serif;">All three are within easy reach of the charging station and there's walk space in between the cars, so I can get to the workbench and outside trash bins without rearranging the fleet. This has me thinking of fresh paint and garage decorations, maybe even that cool flecked epoxy floor finish. So when the day comes to sell the homestead, we can legitimately advertise the three car garage.</span>Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0tag:blogger.com,1999:blog-7704297722315814760.post-41786899614751346992016-03-24T21:48:00.001-07:002016-04-07T20:46:17.500-07:00Seriously, This is Getting Old<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTPPfaDwh66PgSOImcfnq8CGqVzJgE44sfbYrXVo-LhXh_YZXUCgL0UBRE-JocqVO5O-sY4DdCT3hhjUKYBR1hyyLpNIHntTddkPlCC0xm9W6Ave5Opmj3N2wd4dYyZXhZNKzFi4fIJok/s1600/500ohm100watt489_medium.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="243" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTPPfaDwh66PgSOImcfnq8CGqVzJgE44sfbYrXVo-LhXh_YZXUCgL0UBRE-JocqVO5O-sY4DdCT3hhjUKYBR1hyyLpNIHntTddkPlCC0xm9W6Ave5Opmj3N2wd4dYyZXhZNKzFi4fIJok/s320/500ohm100watt489_medium.jpg" width="320" /></a></div>
<span style="font-family: "trebuchet ms" , sans-serif;">Yes, another fried contactor, this time the rear mid-pack unit. It's clear that there is something fundamentally wrong with the precharge setup, and I've changed the circuit scheme three times and still welding contactors shut. One thing that hasn't changed is the precharge resistor. Even though it's been replaced once, the </span><span style="font-family: "trebuchet ms" , sans-serif;">500 ohm 100 watt unit I've been using</span><span style="font-family: "trebuchet ms" , sans-serif;"> may be mis-sized for my 400 volt pack. I still have the precharge resistor and relay that came with the battery pack, and surely it must be a match. Only problem is that I welded those contactors on my first precharge mishap. </span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLQLcASA55mhp3YkEcJZGS2zmD_U6vedExTmuMgi-RllABhdPADA5aH_-9qNhTKK9kMLVE4QtGFDjZzHj6v8Q3QGlp5jFPXSXBLWPSLeGYS4mRBBBpswZP3ybRRfy2X5hvBJB5o8dUPJY/s1600/IMG_4749.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLQLcASA55mhp3YkEcJZGS2zmD_U6vedExTmuMgi-RllABhdPADA5aH_-9qNhTKK9kMLVE4QtGFDjZzHj6v8Q3QGlp5jFPXSXBLWPSLeGYS4mRBBBpswZP3ybRRfy2X5hvBJB5o8dUPJY/s320/IMG_4749.jpg" width="320" /></a></div>
<span style="font-family: "trebuchet ms" , sans-serif;">Fortunately, the Panasonic contactors used in the Better Place pack can be found from time to time on eBay, and I picked up a couple from a Canadian seller at a very reasonable price. I like the packaging on the Better Place </span><span style="font-family: "trebuchet ms" , sans-serif;">contactor/precharge module and since I designed the mount for it in the first place, it went back on pretty easily.</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdsl0E4nVG4lvqIuL5EsW3XN8tsUtnX8KQ4XqL1-L8F3J7uhBj8KMnNWaBfUNsOm_NMXZ-MC_TCilskjpAfa6Aky1OqboLnqnF_FX92yJnS-WD6s0BE3f1OMyLLyd3ZVGkVlKMgEaP47Y/s1600/IMG_4861.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdsl0E4nVG4lvqIuL5EsW3XN8tsUtnX8KQ4XqL1-L8F3J7uhBj8KMnNWaBfUNsOm_NMXZ-MC_TCilskjpAfa6Aky1OqboLnqnF_FX92yJnS-WD6s0BE3f1OMyLLyd3ZVGkVlKMgEaP47Y/s640/IMG_4861.jpg" width="640" /></a></div>
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<span style="font-family: "trebuchet ms" , sans-serif;"> I took the opportunity to ground the shielding on the inverter cables and revise the wiring to the time-delay control relay. This setup certainly looks cleaner than the former one, and all of the terminals and connections are safely contained inside the plastic housing.</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif;">We'll test this in the neighborhood for a bit before we go too far afield, but I'm hopeful that this will solve the precharge challenges. There is lots more I want to do, but this needs to be stable and reliable before moving on.</span></div>
Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com4tag:blogger.com,1999:blog-7704297722315814760.post-60685502391349822642016-02-15T11:19:00.000-08:002016-03-05T07:18:11.618-08:00Tidying Up a Bit<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2bbMtfnc_5GZCy6eaZD__gm8ASTnVvX5Lfop_sQ4IVKw34Nsk-dX4koPimBGzf4sAQdvZ6i18yUJcxDi2R2UagYsoDTwnJhsaq4gGRoj_YX8qVVJQ6yJPyd5k-YRy9QhhshyHImyoiGU/s1600/IMG_4562.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2bbMtfnc_5GZCy6eaZD__gm8ASTnVvX5Lfop_sQ4IVKw34Nsk-dX4koPimBGzf4sAQdvZ6i18yUJcxDi2R2UagYsoDTwnJhsaq4gGRoj_YX8qVVJQ6yJPyd5k-YRy9QhhshyHImyoiGU/s400/IMG_4562.jpg" width="400" /></a><span style="font-family: "trebuchet ms" , sans-serif;">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.</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif;">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</span><span style="font-family: "trebuchet ms" , sans-serif;"> spray </span><span style="font-family: "trebuchet ms" , sans-serif;">p</span><span style="font-family: "trebuchet ms" , sans-serif;">aint 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.</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif;">Here's the view from the other side:</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif;">I'm not entirely happy with the GEVCU cable, but it's a dark color and could be worse. </span><br />
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<span style="font-family: "trebuchet ms" , sans-serif;">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.</span><br />
<span style="font-family: "trebuchet ms" , sans-serif;"><br /></span>Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0tag:blogger.com,1999:blog-7704297722315814760.post-86228555149074966412016-02-09T13:16:00.000-08:002016-02-20T13:09:13.311-08:00More Precharge Challenges<span style="font-family: "trebuchet ms" , sans-serif;">The precharge circuitry on the Porsche has been a challenge since day one. I'm appreciating more and more the well integrated design of the Soliton1 controller in my evTD. I never had to even think about precharge on that because it was built in. Sorry they've left the EV scene.</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif;">You may recall that the first time I powered up the Porsche, <a href="http://porscheev.blogspot.com/2015/09/for-want-of-nail.html" target="_blank">I fried the contactors</a>. Then I <a href="http://porscheev.blogspot.com/2015/09/the-chicken-and-armadillo.html" target="_blank">did it again</a>. Third time is the charm, you say? Well, after 200+ miles I came close to another wholesale cont</span><span style="font-family: 'trebuchet ms', sans-serif;">actor replacement. This time, after a jaunt up the MOPAC (that's a highway here in Austin, so named because it parallels the Missouri Pacific railway line), I parked it and came back a few minutes later to run an errand, turned the key to see only 6 volts register for the pack! That just can't be, so I spot checked some battery cells - all fine - then pulled the contactors yet again to find they worked ok after cycling them a time or two, but the precharge resistor was dead - no reading on the multimeter in the ohm setting. So once again, even though it was in the circuit, no precharge was taking place. The contactors likely would have welded closed if I had put them through one more startup sequence.</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif;">I had wired the precharge resistor using this diagram from the GEVCU manual:</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif;">So my guess is that I either had a defective resistor, or it didn't like being in the circuit full time. After receiving a replacement resistor, I reworked the arrangement adding the yellow high voltage precharge relay to energize the resistor only on precharge and keep it out of play at all other times.</span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6TYbFZz2y5ocHxzycKmgd8UeIyKXhYi2R4mG7mlOLlN9bTPvD1_g2lEe40dnSE4hUab9e8CcuISfdV1S_cmxwfC5UcH08-jUowJ9MKQsMoxwXamKkyWXTkwP-dpcyiLKbpGkX89Z9afs/s1600/IMG_4747.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6TYbFZz2y5ocHxzycKmgd8UeIyKXhYi2R4mG7mlOLlN9bTPvD1_g2lEe40dnSE4hUab9e8CcuISfdV1S_cmxwfC5UcH08-jUowJ9MKQsMoxwXamKkyWXTkwP-dpcyiLKbpGkX89Z9afs/s640/IMG_4747.jpg" width="640" /></a></div>
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<span style="font-family: "trebuchet ms" , sans-serif;">After a quick spin around the block, things seem to be back to normal. We'll give it a more extended test run tomorrow.</span>Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0tag:blogger.com,1999:blog-7704297722315814760.post-43583213450351908272016-01-18T08:49:00.000-08:002016-01-18T09:46:47.076-08:00Baby Needs New Shoes<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBJg2baclgyqsRRqh6e188qpAV99yPtVsLWNVtZAqSaOIq0cNl4YfHch2DZEpwKqiIkKD0E_W6Fsr1gYE9tRgJhvRm12t6vVCnx7-bzEA-MAsr_XRksj68YzHT0Kx2sSFcsMNzPYvIDvg/s1600/IMG_4737.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBJg2baclgyqsRRqh6e188qpAV99yPtVsLWNVtZAqSaOIq0cNl4YfHch2DZEpwKqiIkKD0E_W6Fsr1gYE9tRgJhvRm12t6vVCnx7-bzEA-MAsr_XRksj68YzHT0Kx2sSFcsMNzPYvIDvg/s400/IMG_4737.jpg" width="400" /></a><span style="font-family: "trebuchet ms" , sans-serif;">Checking out from Pro Automotive after the drive shaft repair, Keith noted that the rear tires were showing sidewall cracks and he sure would hate to see a blowout and the trail of sparks when the battery boxes drag the car to a halt. As usual, Keith is right, so we paid a visit to the tire store over the weekend for new shoes. Turns out all four tires were the same age (2009 vintage) and the fronts would be showing signs of dry rot soon enough, so I had all four replaced.</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjx6-TJacXOeqJ_DbV3Y6_SX80ZglXfBPVmHbJdOyYhb3oLdNsIEmr-X6iXJ977Qe3006R83KURlMnLZfep7rzoQFjjwhorHWeTmT_jdVp5ecL-eww-cPhgrrt-SYNoipjyBVUCXFaTbwQ/s1600/IMG_4738.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjx6-TJacXOeqJ_DbV3Y6_SX80ZglXfBPVmHbJdOyYhb3oLdNsIEmr-X6iXJ977Qe3006R83KURlMnLZfep7rzoQFjjwhorHWeTmT_jdVp5ecL-eww-cPhgrrt-SYNoipjyBVUCXFaTbwQ/s400/IMG_4738.jpg" width="400" /></a><span style="font-family: "trebuchet ms" , sans-serif;">The replacements are the same model 195/65 r15 Falken tires that came off. That size seems to be a bit odd and not available from every manufacturer, also sadly unavailable in low rolling resistance tires. Due diligence on Google turns up that Falken, although it sounds vaguely Scandinavian, is the performance brand for Sumitomo Tire company, and pretty well rated on the review sites. I don't know how many miles may have been on the old set, but they showed very little wear for seven year old tires.</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif;">I was pleased with the way Discount Tire handled the whole affair. They let me drive the car into the service bay so I wouldn't have to explain the startup process. They used hand tools for removal and installation rather than pneumatic impact guns, then hand torqued the lugs. They wire brushed the studs and wheel mount areas and even asked where I wanted the balance tape mounted.</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif;">It's probably psychological, but the car seems even smoother, so between the new drive shaft and new shoes, we're making progress toward a more civilized ride.</span>Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0tag:blogger.com,1999:blog-7704297722315814760.post-44470120111641406282016-01-14T14:14:00.001-08:002016-01-15T10:55:15.810-08:00Getting the (half) Shaft<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaahoMbkGHsBLk3ZaudTq_EEhqZKRuXiMuwWxSXVS2Vw81dq3YxLJcxYvy6n0CuM0FqR7OIsC5P1lXBY2Fed3zDsLHIyjg_p52u0D2fsnGgEUdKQEVhm2OfrU9-plLUUDfez_3k2A1KE4/s1600/Happy-new-year-Images-for-vine-flickr-vk.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaahoMbkGHsBLk3ZaudTq_EEhqZKRuXiMuwWxSXVS2Vw81dq3YxLJcxYvy6n0CuM0FqR7OIsC5P1lXBY2Fed3zDsLHIyjg_p52u0D2fsnGgEUdKQEVhm2OfrU9-plLUUDfez_3k2A1KE4/s400/Happy-new-year-Images-for-vine-flickr-vk.jpg" width="400" /></a><span style="font-family: Trebuchet MS, sans-serif;">Happy New Year!</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">I haven't updated this blog for a while, been waiting for resolution on a mechanical issue that reared its ugly head just before Christmas.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">The Porsche had been running GREAT! I had put two hundred miles on it and was using it as my daily driver, running errands around town and buzzing down the highway for appointments downtown. Bit by bit, we were fixing some of the rattles and clunks that always seem to go along with a custom build. As my confidence grew, I figured the time was right to get the wife on board and share the EV grin with her. We drove it out to meet a friend for dinner at our local Applebee's, enjoying the time together and the conversation. As we left the restaurant and turned onto the frontage road, it sounded like a coffee can full of rocks and there was no power going to the rear wheels. The trip home was on the back of a flatbed wrecker with the wife having one of those "I told you so" looks on her face. The tow truck deposited the Porsche in my garage (these guys are good!) and there it sat until the Christmas and New Years activities subsided, all the decorations were put away, and all the leftovers consumed.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">I was fearing the worst, as I tend to do, thinking the likely culprit was the weld on the motor to driveshaft coupler. Finally last week I pulled the inspection plate off the top of the coupler housing (no small feat) and was relieved to see that the coupler looked perfect. That was a huge happiness because I really didn't want to disconnect everything and pull the motor out and then re-engineer the coupler. So the next line of thought and a good bit of Googling led to the suspicion that the driveshaft to transaxle coupler may have worked loose or stripped its splines. That was only slightly less distasteful in that the transaxle would have to be pulled to make that replacement.</span><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJ1Q4fhSlWtP8MgzBYYZExs4_TciYIRJzedOfvMT_o3BFBfv17olXhrfgHYcakrzuCQO76-Ne6EoTt9Hvgq8V7wJ9eanthFngMH-X3iQmAt3kzcL0O-Iw_PL4_Out4VosFXw7nOnRMpC8/s1600/1834.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="305" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJ1Q4fhSlWtP8MgzBYYZExs4_TciYIRJzedOfvMT_o3BFBfv17olXhrfgHYcakrzuCQO76-Ne6EoTt9Hvgq8V7wJ9eanthFngMH-X3iQmAt3kzcL0O-Iw_PL4_Out4VosFXw7nOnRMpC8/s400/1834.jpg" width="400" /></a><span style="font-family: Trebuchet MS, sans-serif;"><br /></span><br />
<span style="font-family: Trebuchet MS, sans-serif;">This morning I had the car towed over to Pro Automotive to have the experts put it on the lift and work their magic. Bob just called and told me the right hand axle shaft had failed. I'm delighted! Not only can the motor and transaxle stay where they are, it's really a pretty straightforward repair.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">We've ordered a replacement that is a bit pricey, but is an OEM quality German manufactured part as opposed to the "remanufactured" ones that I had sourced when we did the conversion. In this case I fear that "remanufactured" is an industry term for "cleaned the gunk off a used one and sprayed on some Rustoleum".</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">A recurring theme among the community of EV conversion guys is the frequent breakage of something in the driveline after the conversion is complete. You may recall that I had a <a href="http://evtd.blogspot.com/2013_10_01_archive.html" target="_blank">transaxle graunch in the evTD</a>, and the same sort of thing has happened with alarming frequency to other EV conversions. No drag racing this time, but with the strong regenerative braking on the Porsche, it's no surprise that there's more stress on the driveline than its thirty year old parts can handle.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">I'm anxious to get the car back in service and already have some plans for improvement. Stay tuned ...</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">UPDATE Friday, January 15, 2016</span></h3>
<span style="font-family: Trebuchet MS, sans-serif;">Bob called to let me know the Porsche was done and ready to be picked up. They shipped the part overnight from somewhere in Illinois and Robert had it installed by 10:00am! Probably couldn't have gotten one from a warehouse in Dallas any quicker. The car runs great and feels smoother than before. It's good to have it back on the road.</span><br />
<span style="font-family: Trebuchet MS, sans-serif;"><br /></span>Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0tag:blogger.com,1999:blog-7704297722315814760.post-75618837417671360142015-11-20T12:05:00.001-08:002015-11-21T06:21:58.414-08:00A Pinch of This, A Dash of That<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcJpfcDYL3DhbUjnWLHYucn1l7kmLP6IFnC90oXfe1PdkhLk2l7Gy-V4Zajq8Wr5HWHTIzw0W5ZVNmuqagVYwGQortFe9f7nomBo0SMtx4raozJecPs-GzUKJQmlpxOkBGZBKEztz-bOU/s1600/dsc00047.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcJpfcDYL3DhbUjnWLHYucn1l7kmLP6IFnC90oXfe1PdkhLk2l7Gy-V4Zajq8Wr5HWHTIzw0W5ZVNmuqagVYwGQortFe9f7nomBo0SMtx4raozJecPs-GzUKJQmlpxOkBGZBKEztz-bOU/s400/dsc00047.jpg" width="400" /></a><span style="font-family: "trebuchet ms" , sans-serif;"></span></div>
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<span style="font-family: "trebuchet ms" , sans-serif;">The Porsche's been home for going on three weeks now, and I'm getting accustomed to driving it. It's been a bit disconcerting to be out on the road with no instrumentation, though; no clue about the voltage, current consumption, temperatures, or state of charge. Only the speedometer from the classic gauge panel functioned, and rather poorly at that.</span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGSO5ttQrTG-A4HobEZYGaRpG2eOsgW41DraBc3h25Ngq7PaSsm0d9M0EY0L4xqgc1JFc9lyze9m-j-dSdz6BR8JNhO4zMhXbNdRikWLgEvSS0CvL3IucJ3TwJYlBWnrGjiiUqUeY6dhw/s1600/combo_medium.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="245" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGSO5ttQrTG-A4HobEZYGaRpG2eOsgW41DraBc3h25Ngq7PaSsm0d9M0EY0L4xqgc1JFc9lyze9m-j-dSdz6BR8JNhO4zMhXbNdRikWLgEvSS0CvL3IucJ3TwJYlBWnrGjiiUqUeY6dhw/s320/combo_medium.jpg" width="320" /></a><span style="font-family: "trebuchet ms" , sans-serif;">Pretty as the they are, the old gauges need to be replaced with something a bit more in keeping with electrifying nature of the car. I chose an Andromeda EVIC (Electric Vehicle Interface Controller) display that is custom designed for the GEVCU controller at the heart of my electric drive. </span><span style="font-family: "trebuchet ms" , sans-serif;">This single display panel covers all of the </span><span style="font-family: "trebuchet ms" , sans-serif;">useful driver </span><span style="font-family: "trebuchet ms" , sans-serif;">information, save for speed.</span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-Jw1GBfqZWbocxmXK3MT2PXsrodcBgMyXyXTLCFrc4TJ23kPpcy7nToNxK0KtFzasf_PPDNqdkw-5eOV0JyHyOlecZeLAb0S45M0Stv2LU6XPR3LkQaCaRKWM_9gfN8nuOH-SuN4r_90/s1600/izl-m9222b_hh_xl.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="254" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-Jw1GBfqZWbocxmXK3MT2PXsrodcBgMyXyXTLCFrc4TJ23kPpcy7nToNxK0KtFzasf_PPDNqdkw-5eOV0JyHyOlecZeLAb0S45M0Stv2LU6XPR3LkQaCaRKWM_9gfN8nuOH-SuN4r_90/s320/izl-m9222b_hh_xl.jpg" width="320" /></a><span style="font-family: "trebuchet ms" , sans-serif;">The speedometer should be at least generally compatible with the digital nature of the EVIC, so an Intellitronix Digital GPS unit in a complementary blue hue was chosen. This speedo also has performance tracking and will measure 0-60, quarter mile, and top speed, along with a trip and cumulative odometer. Add turn signal, high beam, and precharge</span><span style="font-family: "trebuchet ms" , sans-serif;"> indicator lights and we have a full complement of function for the replacement dashboard.</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjN4FtHrkPeozn0rFCTev670CQtZuaaj6pDLhyphenhyphen0WqwKnDAC2hpWimLB6TImDKruKgXvpv16FMLPbmYnHK1nKSym3JV4ys0TTBMgrYlx2k78KrHDStDewu4Dd19rDELdxnZ6mujbOHAKBkU/s1600/IMG_4595.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjN4FtHrkPeozn0rFCTev670CQtZuaaj6pDLhyphenhyphen0WqwKnDAC2hpWimLB6TImDKruKgXvpv16FMLPbmYnHK1nKSym3JV4ys0TTBMgrYlx2k78KrHDStDewu4Dd19rDELdxnZ6mujbOHAKBkU/s320/IMG_4595.jpg" width="320" /></a><span style="font-family: "trebuchet ms" , sans-serif;">To build the new dashboard, we start with ... a board! A scrap of 1/4" plywood will do nicely. I dug out my trusty 40 year old jig saw, got a new blade for it, and proceeded to ruin two blanks before I got to this point. I did cheat and got a 3 1/4" hole saw for the speedometer. Since the speedo needs a 3 3/8" opening, I also picked up a rotary rasp for my drill. New power tools will always warm my heart.</span></div>
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<span style="font-family: "trebuchet ms" , sans-serif;">So here's a trial fit with most of the bits in place:</span></div>
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<span style="font-family: "trebuchet ms" , sans-serif;">And here's the final fitting after many coats of flat black from a rattle can:</span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyegnqHFYotQeVVaSggn247nD4drmAVy2485haSMRwW5qcdvD90Je1GeS5ZtVCtdgYsgFMBkLXHSbEbeg5iavAcTlywtS7JsnOfGV8FxZcCVuG6_YfADe1UY9iKWW5ZsUntmTATVGpwCA/s1600/IMG_4613.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyegnqHFYotQeVVaSggn247nD4drmAVy2485haSMRwW5qcdvD90Je1GeS5ZtVCtdgYsgFMBkLXHSbEbeg5iavAcTlywtS7JsnOfGV8FxZcCVuG6_YfADe1UY9iKWW5ZsUntmTATVGpwCA/s320/IMG_4613.jpg" width="320" /></a><span style="font-family: "trebuchet ms" , sans-serif;">Yet another terminal board was needed to manage all of the connections. The large black box is the GPS controller for the speedometer. The relay turns on the brake lights under regenerative braking. That was actually the first thing I did on this dashboard project because with the aggressive regen produced by the Siemens motor, you can literally drive with only the power pedal. I don't want drivers behind me crawling up my tailpipe (sorry, no tailpipe) when I stop without signaling. The terminal board was installed under the dash in the space vacated by the gas engine Electronic Control Module.</span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQj8-Cuw3iClyB0gEqGT30VvA1h_0HuClRBtns4OnsLOsdf_0B-zqsenV4GDuMPVa6EOttlrP119lyW5P5mIp2X-ppSvKvKUIDu4JrbWu5zB8lfpZoicrNmWtSliOKS55dmB7loujnu7w/s1600/IMG_4615.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQj8-Cuw3iClyB0gEqGT30VvA1h_0HuClRBtns4OnsLOsdf_0B-zqsenV4GDuMPVa6EOttlrP119lyW5P5mIp2X-ppSvKvKUIDu4JrbWu5zB8lfpZoicrNmWtSliOKS55dmB7loujnu7w/s400/IMG_4615.jpg" width="400" /></a><span style="font-family: "trebuchet ms" , sans-serif;">The unit looks pretty nice when in place, but getting it there was a multi-day effort and wiring everything took hours of laying on my back with my feet in the air and squeezing my hands into very tight places with sharp edges.</span></div>
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<span style="font-family: "trebuchet ms" , sans-serif;">All of it was worth the effort, because the effect is really quite stunning.</span></div>
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<span style="font-family: "trebuchet ms" , sans-serif;">Now I need to figure out what's up with the Ah reading, but the rest of the info looks like it's accurate. I was a bit concerned about daytime visibility, but it appears to be a non-issue today</span><span style="font-family: "\22 trebuchet ms\22 " , sans-serif;"> </span><span style="font-family: "trebuchet ms" , sans-serif;">in bright sunlight, and even is readable with sunglasses on - all good. Took the opportunity to remount the steering wheel in a more straight ahead position so I don't feel like I'm driving crabwise down the road. This has been a satisfying refinement of the car, next item will be to dampen the sound on the power brake vacuum pump.</span></div>
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Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com6tag:blogger.com,1999:blog-7704297722315814760.post-31384358308421135792015-11-04T10:04:00.003-08:002015-11-04T10:18:34.692-08:00On the Road Again<span style="font-family: "trebuchet ms" , sans-serif;">Bob called yesterday to let me know the Porsche was ready to be picked up. Pro Automotive had delivered on everything I asked of them and much more!</span><br />
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<tr><td class="tr-caption" style="text-align: center;"><span style="font-family: "trebuchet ms" , sans-serif; font-size: small;">In front of the shop with my Leaf in the background</span></td></tr>
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<tr><td class="tr-caption" style="text-align: center;"><span style="font-family: "trebuchet ms" , sans-serif; font-size: small; text-align: start;">Here's the team that made it all possible: on the left are Colton, Bob, and Keith, three generations of a wonderful family business, with Robert on the right. Many thanks, Guys!</span></td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhN9TzIFhoCwipInmNjr2TMdNGu126vTFsZ-oeF2ZG-EPGztKtmTimIPBr-lQy97TeEDJN8cg7VcZKyYzFQttACGnQNzUGvVxDzlEsqa071Rg9cYMU3sBsIDg7bcFdinmQ4xO3bzMIZjbk/s1600/IMG_4587.jpg" imageanchor="1" style="clear: left; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhN9TzIFhoCwipInmNjr2TMdNGu126vTFsZ-oeF2ZG-EPGztKtmTimIPBr-lQy97TeEDJN8cg7VcZKyYzFQttACGnQNzUGvVxDzlEsqa071Rg9cYMU3sBsIDg7bcFdinmQ4xO3bzMIZjbk/s640/IMG_4587.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;"><span style="font-family: "trebuchet ms" , sans-serif; font-size: small; text-align: start;">Master Craftsman Robert Juarez in front of his creation. Robert did all the fabrication, body, and paint work. He's taken a very personal interest in both of my EV projects and has been a source of great ideas and practical applications.</span></td></tr>
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<tr><td class="tr-caption" style="text-align: center;"><span style="text-align: start;"><span style="font-family: "trebuchet ms" , sans-serif; font-size: small;">PorschEV arrives at home after the short jaunt up Highway 620 and down Anderson Mill Road. The car drives great!</span></span></td></tr>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqjpTe80RppS8n_IqfZnox4wGqEyN_56EDI-vK4co3mei7lXqDzFJSRkvwrtKV1vgF2lppED9yJ9XQjcNwLHKi6IQ6wPqNkdtqG0B3ABpNvZKVIAhoQ3xvx-osU6Km0T_-VouE2ijz1BQ/s1600/IMG_4591.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqjpTe80RppS8n_IqfZnox4wGqEyN_56EDI-vK4co3mei7lXqDzFJSRkvwrtKV1vgF2lppED9yJ9XQjcNwLHKi6IQ6wPqNkdtqG0B3ABpNvZKVIAhoQ3xvx-osU6Km0T_-VouE2ijz1BQ/s320/IMG_4591.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNS5sjgIcapqlvx_1QmXFZzHEWDy88VUHDr0C7ZLaUbovMrNhcuXwGiwzz3ilKd4WrTcl_su2-VdVxtGMbletrWBLms1YJlFhF-ix1SpyDG826uZLuN1mJWD4Ltkifl2wK3efa41quiw0/s1600/IMG_4592.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNS5sjgIcapqlvx_1QmXFZzHEWDy88VUHDr0C7ZLaUbovMrNhcuXwGiwzz3ilKd4WrTcl_su2-VdVxtGMbletrWBLms1YJlFhF-ix1SpyDG826uZLuN1mJWD4Ltkifl2wK3efa41quiw0/s320/IMG_4592.jpg" width="320" /></a></div>
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<span style="font-family: "trebuchet ms" , sans-serif;">The PorschEV takes its place alongside its sister ship, the evTD, both products of the care and craftsmanship of Pro Automotive.</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_jq10ZRyAVersMRXGOPBHHZbDtO_dwOTtBBY2GHEAuM6erVGB76UK5zQWE-RKO_ikDFy36pfVj8NVpj6a-cpUsIby_HYceBzrXxmkPvT_m7CYSn3x6K7hBbgrp3lMcfBCLwzlRA-9PxI/s1600/Scan+1.jpeg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="111" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_jq10ZRyAVersMRXGOPBHHZbDtO_dwOTtBBY2GHEAuM6erVGB76UK5zQWE-RKO_ikDFy36pfVj8NVpj6a-cpUsIby_HYceBzrXxmkPvT_m7CYSn3x6K7hBbgrp3lMcfBCLwzlRA-9PxI/s200/Scan+1.jpeg" width="200" /></a><span style="font-family: "trebuchet ms" , sans-serif;"><br /></span><br />
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<span style="font-family: "trebuchet ms" , sans-serif;"><br /></span><span style="font-family: "trebuchet ms" , sans-serif;">And I can't overlook the role played by <a href="http://evtv.me/" target="_blank">Jack Rickard and EVTV</a>. The <a href="http://store.evtv.me/" target="_blank">EVTV Store</a> was the source for nearly all of the major components inside the PorchEV, and it is Jack's vision, persistence, and the programming skills of the team he's assembled that are making OEM quality parts available for custom conversions like the PorschEV.</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif;">A project like this is never finished, and there is still much to refine, but this can now be done in small chunks while the car is in service. Not The End ...</span>Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com1tag:blogger.com,1999:blog-7704297722315814760.post-41617102654689544652015-11-02T10:03:00.000-08:002015-11-02T10:05:21.213-08:00Details and More Details<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjH10WqLeqgoMGLPY0UyhSpZc2L39eGl79g6m-UH1AMi1zCGa2U6GwKTDHY17bYwL0Rg1JA-o9ygJu7pk0HpHBcm_vhZX_uuAVUNpd4sQID5N66Egor5ORowxlm34EdkQ9V5GwYwlctu4k/s1600/IMG_4575.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjH10WqLeqgoMGLPY0UyhSpZc2L39eGl79g6m-UH1AMi1zCGa2U6GwKTDHY17bYwL0Rg1JA-o9ygJu7pk0HpHBcm_vhZX_uuAVUNpd4sQID5N66Egor5ORowxlm34EdkQ9V5GwYwlctu4k/s400/IMG_4575.jpg" width="400" /></a><span style="font-family: "trebuchet ms" , sans-serif;">Went over to Pro Automotive this morning to do some under-hood work in preparation for the air conditioner bring-up. Found Robert hard at work on the rubber window channels and waist seals.</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif;">The old ones were hardened and brittle to the point they crumbled when they should have flexed. The new rubber is supple and dark and should seal the windows and prevent rattling. A bit of a struggle to install, but Robert figured out how to bend and guide the new parts into the two separate channels in the window frame.</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif;"><span style="font-family: 'trebuchet ms', sans-serif;">My job this morning was to move the power brake vacuum pump valve out of the way. It was directly over and blocking access to one of the air conditioner fill valves.</span></span><br />
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<span style="font-family: "trebuchet ms" , sans-serif;">Also on today's work list is finishing the high voltage wiring for the electric ac compressor so we can test it after it gets its freon charge.</span><br />
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<span style="font-family: "trebuchet ms" , sans-serif;">With the terminal connections done, all that remains is to run some orange accordion loom over the wiring so we're consistent in identifying high voltage cable runs for emergency response personnel. Hope we never need it!</span><br />
<span style="font-family: "trebuchet ms" , sans-serif;"><br /></span>Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0tag:blogger.com,1999:blog-7704297722315814760.post-91911182586727438192015-11-01T09:59:00.000-08:002015-11-01T09:59:08.328-08:00I Love it When a Plan Comes Together<span style="font-family: Trebuchet MS, sans-serif;">Only one picture today, but it's beyond exciting!</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">After two years of gathering parts, planning, head scratching, thinking and rethinking, and trial and error, Robert sends me this and says that the hood closed with plenty of clearance.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">I can't get over how beautiful the front end looks!</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">I'm heading over to Pro Automotive tomorrow morning to finish the wiring for the air conditioning compressor. Now I'm anxious to have a look. There are still many details to take care of, but I think by the end of the week we'll be able to declare victory!</span>Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com2tag:blogger.com,1999:blog-7704297722315814760.post-87960773825111361102015-10-28T13:34:00.000-07:002015-10-29T14:21:51.063-07:00Trial Fit<span style="font-family: Trebuchet MS, sans-serif;">Quick update: One fender and the nose panel are loosely in place, checking for fit.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">The paint and finish on the front is gorgeous! The rest of the car looks faded and dusty now, but Robert thinks it should polish out nicely.</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPL04VwAIaUKNGFEZjkKcQQlpDZNMH_jauRp_k6SBW0zpEl4By7xHnPnUTbMn6HNjK5jQVOP3VDEZopFa46UvPT7VtRNQM0JLEgrOkWji3BRz5oOerdaQkSLJwSy2PFc2yZROzyCRb7_4/s1600/IMG_4565.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPL04VwAIaUKNGFEZjkKcQQlpDZNMH_jauRp_k6SBW0zpEl4By7xHnPnUTbMn6HNjK5jQVOP3VDEZopFa46UvPT7VtRNQM0JLEgrOkWji3BRz5oOerdaQkSLJwSy2PFc2yZROzyCRb7_4/s640/IMG_4565.jpg" width="640" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif;">Still concerned about hood clearance on the front of the inverter, but the fender line is about an inch higher than the reference point on the inner fender wells, so we could just make it.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">Robert has finished the headlamp covers and is working on the nose panel.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">You can't see it, but one air conditioner hose is connected to the compressor and the other is out for fabrication and should be here early next week. Things are happening fast now, I'm very pleased with the progress!</span>Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0tag:blogger.com,1999:blog-7704297722315814760.post-87412624704960108842015-10-26T16:27:00.000-07:002015-10-31T09:35:16.107-07:00Back to the Shop!<span style="font-family: Trebuchet MS, sans-serif;">You'll recall that there were several contactor casualties from the precharge drama, along with some mysterious memory loss in the charger and DC/DC controllers. First the precharge situation: after frying the second set of contactors, I wired a couple of indicator lights to check the GEVCU precharge function and noted that they BOTH came on momentarily when the system was powered up, then followed the precharge sequence. That momentary inrush of current was all it took to weld the contactors closed. I also noticed during that momentary start-up period that the cooling fan spun just a bit.</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZT4iKj-_ThJye5HJkrSaMGDeAgJPbrT0-oqBW-RuUHq0VcQI82bNUXDo8tkl1vxF2r_HqrL48Tr0cm-ZSSxLiMF0ocQoPko47s_hWImFpqhHlf6bfOnElh0rc2vOHuc42vY3YAUihUKM/s1600/IMG_4529.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZT4iKj-_ThJye5HJkrSaMGDeAgJPbrT0-oqBW-RuUHq0VcQI82bNUXDo8tkl1vxF2r_HqrL48Tr0cm-ZSSxLiMF0ocQoPko47s_hWImFpqhHlf6bfOnElh0rc2vOHuc42vY3YAUihUKM/s320/IMG_4529.jpg" width="320" /></a><span style="font-family: Trebuchet MS, sans-serif;">At EVCCON, I checked with Collin Kidder who wrote much of the GEVCU code, and he said he had heard of this from several other guys and that it seemed that in the split second it took for the processor to boot up, the mosfets that were supposed to connect to ground under program control, all connected by themselves. Not good.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">Nick Smith suggested taking the GEVCU out of the equation by using a time-delay relay to control the precharge sequence. I found <a href="http://www.amazon.com/HELLA-996152151-0-900s-Delay-Control/dp/B003C508Y8" target="_blank">this</a> on Amazon that seemed to fill the bill, and picked up two more contactors from the EVTV store. </span><span style="font-family: 'Trebuchet MS', sans-serif; text-align: center;">All mounted to a panel, it looks like this:</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">The contactor on the left closes at startup connecting the negative side of the pack to the inverter. The gold colored precharge resistor then restricts the current flow from the positive side to allow the capacitors to come up to pack voltage at a lower current. The time delay relay closes after roughly five seconds and connects the positive contactor allowing full current flow. An indicator light is wired to the normally closed terminal of the relay so there is a visual cue on the dashboard while the precharge is taking place. All of this works very well and has kept the contactors healthy.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">In the controller situation, Jack Rickard had reloaded the flash memory on my DC/DC controller and re-enabled the WiFi function on my GEVCU while we were at EVCCON. I reinstalled the DC/DC when I got home and BLAM! lost the memory again. Jack asked me to return the controller along with the Volt APM. He found that the plug was bad, and built a whole new controller. Thanks Jack - great customer service!</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">The DC/DC controller came in a new style enclosure that included tabs that made it so much easier to mount.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">While all that was going on, I noticed that the charge controller kept losing its settings. So here we have wiped out the flash memory on the DC/DC controller twice, the EEPROM on the charge controller any number of times, and the WiFi function on the GEVCU. What's the common denominator? The USB cable! I broke out a new USB cable, one with gold contacts and perhaps a little better quality, and everything works just fine now. Moral of that story, don't overlook level 1 diagnostics; Is it plugged in? Is the cable good?</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">Took son Freddy and daughter-in-law Tiffany for a ride around the block and I'm becoming more and more pleased with the way this car drives. I was wrapping up some of the detail work, installing the hood release cable, running wiring for the dashboard, and generally tidying up the motor compartment when Bob called from Pro Automotive to let me know that they had a relatively slow week ahead and this would be a perfect time to get the car in for reassembly of the front bodywork. Called for a flatbed and now the PorschEV is in for finishing.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">After a full year of work, this project is coming to completion. There is plenty of tweaking and tuning ahead, but the end is in sight.</span><br />
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Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0tag:blogger.com,1999:blog-7704297722315814760.post-7110318972626729622015-10-15T13:08:00.000-07:002015-10-16T04:26:42.902-07:00The EVCCON that wasn't ... or WAS IT?<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHO8c77jaoOXFiiRmF52v72krgvJt2LPX1y9VQAGsvVrFM7zA9jqZUwW2ZpdezaO6ICZyBjhqbtG_UVpR8KfKYN07qmeXB4NszPHm9HkFkkoI0Zyr2V9cUlPLaawzxnqeclhQJ1qjS_Xc/s1600/IMG_4497.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHO8c77jaoOXFiiRmF52v72krgvJt2LPX1y9VQAGsvVrFM7zA9jqZUwW2ZpdezaO6ICZyBjhqbtG_UVpR8KfKYN07qmeXB4NszPHm9HkFkkoI0Zyr2V9cUlPLaawzxnqeclhQJ1qjS_Xc/s320/IMG_4497.jpg" width="240" /></a></div>
<span style="font-family: Trebuchet MS, sans-serif;">After announcing the cancellation of EVCCON 2015, Jack Rickard noted with some bemusement that it just didn't want to be cancelled. He left the door open by offering his shop for an open house to whomever might care to visit, and it looks like pretty much all of us did. I had a hotel room and rental car all lined up, so I figured, "for a couple of days, why not?". And since the Porsche wasn't going to make it, I'd be traveling light anyway. Others like Michael Brown and Nick Smith were in the middle of global tours, coming from Thailand and New Zealand respectively. They were going to be there regardless. Speakers like John Hardy from the UK offered to do their thing anywhere there was a laptop and a projector, so Jack set up the showroom/studio of his shop classroom style and EVCCON 2015 took on a life of its own.</span><br />
<span style="font-family: Trebuchet MS, sans-serif;"><br /></span><span style="font-family: Trebuchet MS, sans-serif;">Once again Michael Brown did a superb job of live blogging the proceedings, so I'll direct you to his site again for the synopsis:</span><br />
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<span style="color: #141823; font-family: helvetica, arial, sans-serif; font-size: 14px;">Day -1: </span><a href="http://l.facebook.com/l.php?u=http%3A%2F%2Fporsche914e.blogspot.com%2F2015%2F09%2Fevccon-2015-day-1.html&h=xAQHaw0AlAQGpQVQVwHx3HlE50S4qyAxiqCU4k5oHBOggmw&enc=AZPLGYZKU96eeXSg3gIceF0BzpQtueHtNyTfljfyGRLJvlCMaKrV4ANrpFFTqLBBa8sPNOBDN0RgnLIzuK8IY77LR_SehAfQcod5Hr_9XXSoU_6nr2C1XNVkU9a7vKrRQ4gDqneoBSNBWdK-oOx43lzLrrdfoJAmBYUtejIcpEcWZSH4-rwqeSuYuEoI1zqct0oJAlT4TOzL5qz2t4a2pTFk&s=1" rel="nofollow" style="color: #3b5998; cursor: pointer; font-family: helvetica, arial, sans-serif; font-size: 14px; text-decoration: none;" target="_blank">http://porsche914e.blogspot.com/20…/…/evccon-2015-day-1.html</a><br />
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Day 0: <a href="http://porsche914e.blogspot.com/2015/09/evccon-2015-day-0.html" rel="nofollow" style="color: #3b5998; cursor: pointer; text-decoration: none;" target="_blank">http://porsche914e.blogspot.com/20…/…/evccon-2015-day-0.html</a></div>
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Day 1: <a href="http://porsche914e.blogspot.com/2015/09/evccon-2015-day-1_30.html" rel="nofollow" style="color: #3b5998; cursor: pointer; text-decoration: none;" target="_blank">http://porsche914e.blogspot.com/…/09/evccon-2015-day-1_30.h…</a></div>
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Day 2: <a href="http://porsche914e.blogspot.com/2015/10/evccon-2015-day-2.html" rel="nofollow" style="color: #3b5998; cursor: pointer; text-decoration: none;" target="_blank">http://porsche914e.blogspot.com/20…/…/evccon-2015-day-2.html</a></div>
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Day 3: <a href="http://porsche914e.blogspot.com/2015/10/evccon-2015-day-3.html" rel="nofollow" style="color: #3b5998; cursor: pointer; text-decoration: none;" target="_blank">http://porsche914e.blogspot.com/20…/…/evccon-2015-day-3.html</a></div>
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Day 4: <a href="http://porsche914e.blogspot.com/2015/10/evccon-2015-day-4.html" rel="nofollow" style="color: #3b5998; cursor: pointer; text-decoration: none;" target="_blank">http://porsche914e.blogspot.com/20…/…/evccon-2015-day-4.html</a></div>
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<span style="font-family: Trebuchet MS, sans-serif;"><span style="color: #141823;">The session room was comfortably full and the information exchange with speakers and other attendees was more than worth the trip. </span></span></div>
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<span style="font-family: Trebuchet MS, sans-serif;"><span style="color: #141823;">Jack's direction for EVTV is all about making OEM components accessible to DIY guys like me, so that was the focus of the presentations and most of the break time chatter in the shop. A highlight of my last afternoon was the demonstration of a working Tesla drive train.</span></span></div>
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<span style="font-family: Trebuchet MS, sans-serif;">And there were cars - here's a sample:</span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFd8moghNoMjOJkGyMhsKP7N3tUHhCVr62msY3tvRJ46rdFVjuDc78n_SrlbV6ljkCZ3xXTYDZKobHSlJLUknl8ANY8TY27FScwle4gkdC-PStB2jP9C2sqGHiE2zy-a5SBL4ubmaJUp0/s1600/IMG_4485.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFd8moghNoMjOJkGyMhsKP7N3tUHhCVr62msY3tvRJ46rdFVjuDc78n_SrlbV6ljkCZ3xXTYDZKobHSlJLUknl8ANY8TY27FScwle4gkdC-PStB2jP9C2sqGHiE2zy-a5SBL4ubmaJUp0/s320/IMG_4485.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_KTzD-5X3E7QFiRUuIKf4UHByAFeuBaLLdLH0ZvMLv65bf_laxhmNN1wTLUkx3WNXYyaOLH3NeXU-b3DSxuo2qttlT2ycXEZi9xNZ4ylCG4sBf4-2-TFdkRDUzG1c_x8O1SGBH0gTfjc/s1600/IMG_4486.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_KTzD-5X3E7QFiRUuIKf4UHByAFeuBaLLdLH0ZvMLv65bf_laxhmNN1wTLUkx3WNXYyaOLH3NeXU-b3DSxuo2qttlT2ycXEZi9xNZ4ylCG4sBf4-2-TFdkRDUzG1c_x8O1SGBH0gTfjc/s320/IMG_4486.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3pmRiNg9AkOfy0SW0p__o-kCE-bo2FEHYmKjOphcO53s87sYNsSuVi6kRppQkEBbw6dP1zrcjC_PftXg-H7YHgcRsDcusUdKueL6hfXjCnJBBrFYxs6pjpwBTeejQ0O2sLelRb4-QgJY/s1600/IMG_4490.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3pmRiNg9AkOfy0SW0p__o-kCE-bo2FEHYmKjOphcO53s87sYNsSuVi6kRppQkEBbw6dP1zrcjC_PftXg-H7YHgcRsDcusUdKueL6hfXjCnJBBrFYxs6pjpwBTeejQ0O2sLelRb4-QgJY/s320/IMG_4490.jpg" width="320" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif;">All had been to EVCCON before, but it was good to see them again. Most had some detail improvements, and that's what makes these things fun. I'm disappointed that my Porsche wasn't ready in time because it really models the new direction, being fit almost entirely with OEM components. I brought along some problematic components that needed attention, and Jack was more than kind to give me his time to reload software and reconfigure settings. More on that in a future post.</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNLiVSInCWsEeZ_hFELRzWn6rnmifej8MgfkP1J3bBJCmi-8dJUtHuLe2VOOmnoYQ-Mx2y4F_xxK_Bv9D4ufb0Ec7WLX36IzZtGKIwXcG0Cx7Gaz9I_zt6Qq6b3KKBqpOgCWVPe6E8FOM/s1600/IMG_4519.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNLiVSInCWsEeZ_hFELRzWn6rnmifej8MgfkP1J3bBJCmi-8dJUtHuLe2VOOmnoYQ-Mx2y4F_xxK_Bv9D4ufb0Ec7WLX36IzZtGKIwXcG0Cx7Gaz9I_zt6Qq6b3KKBqpOgCWVPe6E8FOM/s200/IMG_4519.jpg" width="200" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtjX6gIZz5gyktwd0rPdM9pyI0bgjzE_ExYx4T_W4cqlCq_2UPgttMHrAMO2gX1I2w0jyQEsEstIp4TOVhKIzbg7tcBOmdo9rQv1DbiiDCs22mh7Brv9WN7FX0HWP7hzAcNbhIKWNUoO4/s1600/IMG_4526.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="200" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtjX6gIZz5gyktwd0rPdM9pyI0bgjzE_ExYx4T_W4cqlCq_2UPgttMHrAMO2gX1I2w0jyQEsEstIp4TOVhKIzbg7tcBOmdo9rQv1DbiiDCs22mh7Brv9WN7FX0HWP7hzAcNbhIKWNUoO4/s200/IMG_4526.jpg" width="150" /></a><span style="font-family: Trebuchet MS, sans-serif;">In the previous four years of EVCCONs, the Thursday night barbecue at the Rickard estate had rained out. Not so for the EVCCON That Wasn't. Beautiful autumn weather and a spectacular setting overlooking the Mississippi river were on tap this year.</span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFQ2UbcaNnBMbcZnpD7YC28QNIJMG21Fde1CSIiAtCrAeOI8QO9jpZBsOMK2CNqZWuSAGmN1hfpnV41EXz2KTyXZshyphenhyphen0Hd6oDhAfK-W8Ir1hrLkOR0Oo94vTQ5DGExkbXmMv8dnmZRY0w/s1600/IMG_4517.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFQ2UbcaNnBMbcZnpD7YC28QNIJMG21Fde1CSIiAtCrAeOI8QO9jpZBsOMK2CNqZWuSAGmN1hfpnV41EXz2KTyXZshyphenhyphen0Hd6oDhAfK-W8Ir1hrLkOR0Oo94vTQ5DGExkbXmMv8dnmZRY0w/s320/IMG_4517.jpg" width="320" /></a><span style="font-family: Trebuchet MS, sans-serif;"><span style="color: #141823;">Many of the EV conversions made the short trip from the EVTV shop, and looked perfectly at home in front of the garage where the early shows were shot.</span></span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJj9Q2lrsij10dH1Zk5R6HU9j2SYB06EWjNIjQPX49l2R-c7a-YMOOfr_8iw6VxPaiDDK0GlhJzjaNq5aF5AXUruiTQi6gS56yKFXMO1lVi0Czchyc4L4uNFOs9JjRiMuWZGCY9AA25VQ/s1600/IMG_4521.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJj9Q2lrsij10dH1Zk5R6HU9j2SYB06EWjNIjQPX49l2R-c7a-YMOOfr_8iw6VxPaiDDK0GlhJzjaNq5aF5AXUruiTQi6gS56yKFXMO1lVi0Czchyc4L4uNFOs9JjRiMuWZGCY9AA25VQ/s320/IMG_4521.jpg" width="320" /></a></div>
<span style="font-family: Trebuchet MS, sans-serif;"><span style="color: #141823;">Of course Jill's Tesla looks right at home, because it is.</span></span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFvYtZVV7hL1svtIP8I3z7wvxAo-jo38dpwN8tQ9zo6xmXqrs68UW_dFNzYLUYDxs794BryeNj7GbPHBwPOaGoBubaRik356CJfM4Key6XQNbi5w5OOa6A6yNL5OvCohegO4Namb_bafg/s1600/IMG_4522.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFvYtZVV7hL1svtIP8I3z7wvxAo-jo38dpwN8tQ9zo6xmXqrs68UW_dFNzYLUYDxs794BryeNj7GbPHBwPOaGoBubaRik356CJfM4Key6XQNbi5w5OOa6A6yNL5OvCohegO4Namb_bafg/s640/IMG_4522.jpg" width="480" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif;"><span style="color: #141823;">On a cool October evening, the fire pit was a welcome gathering spot. I said my farewells after the dinner because I was heading back to Austin in the morning, but EVCCON 2015 continued on without me. I hope we have not seen the last of these events, because all of us work in relative isolation and hunger for the opportunity to hang out with others who share our passion.</span></span><br />
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Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com2tag:blogger.com,1999:blog-7704297722315814760.post-49434032635439921742015-09-18T17:04:00.001-07:002015-09-18T17:09:19.989-07:00The Chicken and the Armadillo<span style="font-family: Trebuchet MS, sans-serif;">One of the first Texas jokes my then middle school daughter picked up was:</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">Why did the chicken cross the road?</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">To show the armadillo it could be done!</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">The number of armadillo frisbees on Texas highways is proof that for those poor creatures, it's just not in the cards. I'm told that when startled by an oncoming car, armadillos jump straight up in the air to perfect bumper height. Unfortunate.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">I tell that story to show you this:</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLeFk_GTdcUoxQEde51X079I35LC93WiLOgZ9U_dU-Z8vFlnruLzrhBlLfaTkFrmu3L6Yesa3-yI_t-dEloWeqnuMVCjb23hBRRj2jXZdBVA0vG3ztOSsyvtDNe0z5lfTfxNg7Dil7EFY/s1600/IMG_4307.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLeFk_GTdcUoxQEde51X079I35LC93WiLOgZ9U_dU-Z8vFlnruLzrhBlLfaTkFrmu3L6Yesa3-yI_t-dEloWeqnuMVCjb23hBRRj2jXZdBVA0vG3ztOSsyvtDNe0z5lfTfxNg7Dil7EFY/s640/IMG_4307.jpg" width="640" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif;">Notice anything different?</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">It's facing the other direction!</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">I'm afraid that I did not have a camera crew on hand to capture the first drive, but I needed to show myself that it could be done. It was once around the block and back in the garage. Didn't want to alarm the local traffic patrol with a car that's basically naked in front. </span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">The good news is that the low hanging battery cage didn't scrape at the end of the driveway. The regen braking will take some getting used to and I suspect that I'll be fiddling with the throttle mapping to get it just right, but my first impression is that it's a smooth and civilized ride.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">Now for jumping up to bumper height:</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">Here is the new configuration for the contactor and precharge relay:</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjd0lvJdZDtLcI2eSxR-0rFYk_jJT1EdGpiI5i8NrpEgLwwtmyU6CBg40I6JG3CFd4IZsqpJ_YBeLF3SUBgfGgBiW3oOnvh3NHV80YSuaeVt9p5mMdPEyo8i9psQ94P_T4OuiPHCosydOw/s1600/IMG_4308.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjd0lvJdZDtLcI2eSxR-0rFYk_jJT1EdGpiI5i8NrpEgLwwtmyU6CBg40I6JG3CFd4IZsqpJ_YBeLF3SUBgfGgBiW3oOnvh3NHV80YSuaeVt9p5mMdPEyo8i9psQ94P_T4OuiPHCosydOw/s640/IMG_4308.jpg" width="640" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif;">It's considerably more compact than the Better Place contactor module it replaces. I plan to make a cover for it, painted black of course so it disappears.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">Pretty as it is, I still don't have the precharge routine figured out - arc welded both this brand new contractor and the one in the back. As long as they are stuck in the closed position, I figured "Why not take it around the block?" And I did, despite the non functional DC/DC converter and ruined contactors. And it was pretty darned satisfying.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">We're leaving on a week's vacation tomorrow for a tour of the upper Mid-West with my parents, visiting places that have memories from their childhood. Now I can relax and enjoy the trip knowing that I've at least had one successful spin around the block.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">The week after, I'm driving up to Cape Girardeau to participate in the EVCONN that wasn't. Jack Rickard has invited anyone interested to drop by for an open house at his shop. I'll be able to consult with the best and brightest on what I'm doing wrong, and pick up replacement parts while I'm there.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">When I get back, we're going to make this armadillo fly!</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;"><br /></span>Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com1tag:blogger.com,1999:blog-7704297722315814760.post-9583326175873722912015-09-18T04:22:00.001-07:002015-09-18T04:36:22.564-07:00Disappointment Part Deux<span style="font-family: Trebuchet MS, sans-serif;">The ink was still wet on my prior posting when Jack Rickard announced the cancellation of EVCCON 2015. Seems the liability insurance bond required for holding an event like this fell through and at this late date that's not recoverable.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;"><a href="http://evtv.me/2015/09/evccon-2015-cancellation" target="_blank">Details here.</a></span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">Jack did offer his shop for an open house that week and since I still have a hotel room reserved, I think I'll drive up for at least a couple of days to hang out with my EV pals.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;"><br /></span>Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0tag:blogger.com,1999:blog-7704297722315814760.post-6882862936216405912015-09-17T18:26:00.000-07:002015-09-17T18:31:26.062-07:00Disappointment<span style="font-family: Trebuchet MS, sans-serif;">No pictures - not a lot to say. The Porsche won't be ready to take to EVCCON this year. The replacement contactor and precharge resistor/relay arrived late Tuesday. Spent all day Wednesday crafting a new mount for them in place of the arc-welded ones. That was all fine.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">Also fine was the charger: it started up exactly as I had planned and loaded in 35 amp hours of energy, then terminated exactly as it was supposed to. The charge controller seems to be losing its configuration parameters when powered off, but otherwise ok.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">I did notice that the 12 volt battery was dropping in voltage even though the DC/DC converter seemed to be running - at least the fan was spinning. When I plugged the laptop in to the controller, nothing, nada, pushing up daisies, pining for the fjords. You get it, casters up. I know it was working when installed, don't have an explanation for this one, but wasted the better part of today trying to get it to wake up.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">So it's an extended game of Whack-A-Mole, and I only have one day left to get it rolling on its own power. With some regret, I decided to cancel the truck and trailer rental and go to EVCCON as a civilian this year. I will enjoy hanging out with my EV pals, and have a much better sorted vehicle to take next year.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">Even so, it's a bummer ...</span>Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0tag:blogger.com,1999:blog-7704297722315814760.post-71671426525893332602015-09-14T14:54:00.000-07:002015-09-18T04:29:20.666-07:00Small Fixes While Waiting for the Big Fix<span style="font-family: Trebuchet MS, sans-serif;">The replacement contactor, precharge resistor and relay are on the UPS truck scheduled for delivery by end of day tomorrow. In the mean time, I've tackled some of the smaller chores that needed to be done to get everything ready for the road.</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQcoauTLWe_ctWg2tTvuKiaao68eaG5eWK1bPkdnYFhweFNbTIivYP2Sr-1sieoHyNE4fYiCHxJ8dP-A14T7rzmVHST7wkvCeYgNObn62z3yNCJnW1n2qG8hZQGfrLoeH3F526zZ4Zlss/s1600/IMG_4306.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQcoauTLWe_ctWg2tTvuKiaao68eaG5eWK1bPkdnYFhweFNbTIivYP2Sr-1sieoHyNE4fYiCHxJ8dP-A14T7rzmVHST7wkvCeYgNObn62z3yNCJnW1n2qG8hZQGfrLoeH3F526zZ4Zlss/s200/IMG_4306.jpg" width="200" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyhkpAOg-OYg3Ux5WKQSdeDj5gI5wnk1uI_qfwEFxg4HjmrVgiEBdQ687EWPb_iT-9il7JJ7s0tvSIZ4qi8aE8JmlMmPMKN7RtwGtJY5o4FSAwWtlGdKoLaYoqJPG0kI2iznECZvk_QvE/s1600/IMG_4305.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyhkpAOg-OYg3Ux5WKQSdeDj5gI5wnk1uI_qfwEFxg4HjmrVgiEBdQ687EWPb_iT-9il7JJ7s0tvSIZ4qi8aE8JmlMmPMKN7RtwGtJY5o4FSAwWtlGdKoLaYoqJPG0kI2iznECZvk_QvE/s200/IMG_4305.jpg" width="200" /></a><span style="font-family: Trebuchet MS, sans-serif;">I installed the tail light assemblies on Saturday. They use a tar-like windshield seal instead of gaskets. The windshield seal comes in a roll with a wax paper separator between the 3/8" thick seal. It's pretty messy, but should be water tight. Once cleaned up, it looks as if it just came from the factory.</span><br />
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<span style="font-family: 'Trebuchet MS', sans-serif;">I spent most of Sunday afternoon working on the hood release cable, only to realize that it was frayed with a halo of strands making it impossible to snake through behind the carpet. It's replacement has also been ordered and should arrive midweek as well.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">The tail lights don't light yet, I'm thinking they need the front running lights and turn signals to complete the circuits. I did solve the mystery of the pop up headlights, though, and probably cured the intermittent nature of the power windows. All it took was crawling into a heroically</span><span style="font-family: 'Trebuchet MS', sans-serif;"> contorted position on my back under the dashboard. Oh, and finding the correct fuse reference charts online. These look like they came from the owners manual. How did we ever get by without Google? </span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcYEzJu-KaCOF8e21KSmnSMKgmhVseY9KYROaWB67TRRC4gYr3DT2zqR8iM3AY7JB1_YqFRpxC77aRP4Nf6VisaOY2AeY0X1hhXTjoJs8QzXX5atvvLCD6rHAflzwepZ9n13F5OrP6_dA/s1600/RELAY%252Bposition1337733394.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="452" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcYEzJu-KaCOF8e21KSmnSMKgmhVseY9KYROaWB67TRRC4gYr3DT2zqR8iM3AY7JB1_YqFRpxC77aRP4Nf6VisaOY2AeY0X1hhXTjoJs8QzXX5atvvLCD6rHAflzwepZ9n13F5OrP6_dA/s640/RELAY%252Bposition1337733394.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNWPeaQefaB5ZYpXlnnC252iJZz3xe1DfmlF0P_x5nQJEInb7riE7fD-GyfuQbRwbQKLaQ2b5R-ntn7eI7v-TjVxoMBCLe94NNYVPAZoyMfuU1y4xa6GGB8QSHwqPxb7L4oLTkU9DjO80/s1600/FUSE%252Bchart1337733562.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="448" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNWPeaQefaB5ZYpXlnnC252iJZz3xe1DfmlF0P_x5nQJEInb7riE7fD-GyfuQbRwbQKLaQ2b5R-ntn7eI7v-TjVxoMBCLe94NNYVPAZoyMfuU1y4xa6GGB8QSHwqPxb7L4oLTkU9DjO80/s640/FUSE%252Bchart1337733562.jpg" width="640" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif;">Now that I know where to look for the retractable headlight fuse, here's what I found:</span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhs5dVon2DSQUo2NIZzixRCgWz_7Uy2FBi5tNvKY-TgEBLpAYRMAab-2jfs0yYaPuS9TgcsZWa6dmHUiIv74XkULst-MlwNVzA_6tORsX-v4O1twrD67s6T2IcTkVEch8rLRXn6Ywe5624/s1600/IMG_4300.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhs5dVon2DSQUo2NIZzixRCgWz_7Uy2FBi5tNvKY-TgEBLpAYRMAab-2jfs0yYaPuS9TgcsZWa6dmHUiIv74XkULst-MlwNVzA_6tORsX-v4O1twrD67s6T2IcTkVEch8rLRXn6Ywe5624/s320/IMG_4300.jpg" width="288" /></a><span style="font-family: Trebuchet MS, sans-serif;">It's obviously blown, and the fact that it's an 8 amp fuse in a 16 amp circuit might have something to do with that. Checking the rest of the fuses lead to the realization that they were placed pretty randomly. These ceramic euro fuses are the same as the ones used in the VW Beetle, not surprising given the close ties between VW and Porsche back in the day. I picked up an assortment of the fuses and used most of them.</span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNivoqZ09N7BZSjBotpPj8HMfypYMdW77rOriH4YlYKjQ1oaN9cCc8e-aOsf7lqDiVtVOfujc1qwuC598giAp-8MxyK-Y0JnSs0UNHaqcJJbcx1gToeDj0FqdCFph0lrknmc2ThiQI1MU/s1600/IMG_4304.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNivoqZ09N7BZSjBotpPj8HMfypYMdW77rOriH4YlYKjQ1oaN9cCc8e-aOsf7lqDiVtVOfujc1qwuC598giAp-8MxyK-Y0JnSs0UNHaqcJJbcx1gToeDj0FqdCFph0lrknmc2ThiQI1MU/s200/IMG_4304.jpg" style="cursor: move;" width="200" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhx2Bz7XjBFFi7TtLBnUn-drFhnZ79QOA85lDEe6uPoUaCx0TJ7ENpL7CQE18Glk8hIRDEUlNdf8blb7eJZ_LymkVNDgadMmS6mIhphyfxkmwS6fpG5zATusJPcAXuzoRrf7AKokKbvetQ/s1600/IMG_4301.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhx2Bz7XjBFFi7TtLBnUn-drFhnZ79QOA85lDEe6uPoUaCx0TJ7ENpL7CQE18Glk8hIRDEUlNdf8blb7eJZ_LymkVNDgadMmS6mIhphyfxkmwS6fpG5zATusJPcAXuzoRrf7AKokKbvetQ/s400/IMG_4301.jpg" width="300" /></a><span style="font-family: Trebuchet MS, sans-serif;">Some were just questionable. The new one's on the left - what's with the narrow fuse link in the old one?</span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPC4zkNeg4UeDPDyvF6G-hCQHGgj33A43WJelJVZwl82ZKNGEAKe-H4KaD_MO88IH7unl3DnKEtJxWMyar_BbUEOWeQ_SCtGC6rdp-tvehMwg6KDaM3W_RiyupqmB_CiiaKQdHfCwPa2c/s1600/IMG_4302.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPC4zkNeg4UeDPDyvF6G-hCQHGgj33A43WJelJVZwl82ZKNGEAKe-H4KaD_MO88IH7unl3DnKEtJxWMyar_BbUEOWeQ_SCtGC6rdp-tvehMwg6KDaM3W_RiyupqmB_CiiaKQdHfCwPa2c/s320/IMG_4302.jpg" width="240" /></a><span style="font-family: Trebuchet MS, sans-serif;">Others were just scary, but creative. Kind of like putting a penny behind an old fashioned screw-in house fuse (if you're old enough to remember such things), someone improvised this replacement fuse by cutting a piece of wire and splaying the uninsulated wire strands over the fuse ends. It certainly would complete the circuit, but defeat the purpose for the fuse. This one was in the power windows slot which calls for a 16 amp fuse. Easy to see why the power windows only worked occasionally. Now they'll actually go up and down twice in a row and then do it again!</span></div>
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<span style="font-family: Trebuchet MS, sans-serif;">Almost 30 years of wear and tear have taken their toll on a lot of the convenience items. It looks like I'll be replacing all the interior light fixtures - they're all the same - and only one out of four lights up and dimly at that.</span></div>
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<span style="font-family: Trebuchet MS, sans-serif;">Tomorrow, more clean up and Wednesday we'll hope to get this thing on the road!</span></div>
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Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0tag:blogger.com,1999:blog-7704297722315814760.post-11081170799486760162015-09-10T17:54:00.000-07:002015-09-10T18:12:05.695-07:00For Want of a Nail<span style="font-family: Trebuchet MS, sans-serif;">So near yet so far.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">Yesterday was focused on completing the battery pack area in the rear under the hatch. There was a good bit of fabrication involved and I'm really pleased with the results. </span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzBPwWeRj8EFsNe6004KubXDZpvaTaa3DFZlBzJoydJLNdgI1TtxI8DKO14MIvkCyBBkUXCDmSIZLY6rgn6Ij-QXgRahdYN6x_td7ftNSETDGmSkRW2StT3hQ5-cqM453l7gqU17LBLbo/s1600/IMG_4285.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzBPwWeRj8EFsNe6004KubXDZpvaTaa3DFZlBzJoydJLNdgI1TtxI8DKO14MIvkCyBBkUXCDmSIZLY6rgn6Ij-QXgRahdYN6x_td7ftNSETDGmSkRW2StT3hQ5-cqM453l7gqU17LBLbo/s400/IMG_4285.jpg" width="400" /></a><span style="font-family: Trebuchet MS, sans-serif;">First, the Nissan master disconnect/fuse unit was installed on the left of the pack.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKWyHt_4ptPmQiaCojy2M9eCvfVd0QntJLU8cvOFpRPwKow53O_Axu_qBoV02m9jKoKi-YlgHKKGp5Lqk9x9J0EdVNc3x5mS991Y9nYjWcY3x8D1P7BLXop_ckFJTTpu-cZaqopNO1h9Y/s1600/IMG_4286.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKWyHt_4ptPmQiaCojy2M9eCvfVd0QntJLU8cvOFpRPwKow53O_Axu_qBoV02m9jKoKi-YlgHKKGp5Lqk9x9J0EdVNc3x5mS991Y9nYjWcY3x8D1P7BLXop_ckFJTTpu-cZaqopNO1h9Y/s400/IMG_4286.jpg" width="400" /></a> Then the DC/DC Converter control box with fuse and AVC2 charge control on the right. The red circular device on the edge is an inertia switch to shut off power in the event of an impact. The little red thing sticking out behind it is a switch for the enable signal. I connected the normally closed terminal of the AVC2 relay to the enable line of the GEVCU to prevent driving off with the charge cord attached. Turning off the enable switch will prevent the car from running. It's a rudimentary security feature, and our little secret. </span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">There is more hiding beneath this shelf: the mid-pack contactor and a terminal strip to connect the J1772 charging port with the charger and controller. The spaghetti will be out of sight down here.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">Viewed as a whole, I think the battery bay looks tidy and businesslike.</span></div>
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<span style="font-family: Trebuchet MS, sans-serif;">With all the cabling in place, it was time to power up. Just as I turned the switch, there was a clap of thunder outside and I couldn't help thinking ...</span></div>
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<span style="font-family: Trebuchet MS, sans-serif;">All the pumps were pumping and pack voltage read correctly when turned on, then showed zero when off. Charging started up when the J1772 was plugged in. All good. So I went off for a late celebratory supper with plans to finalize the configuration in the morning and maybe take the first spin around the block.</span></div>
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<span style="font-family: Trebuchet MS, sans-serif;">Alas, was not to be. I calibrated the throttle and power cycled the GEVCU, but noticed that my multimeter was still showing full pack voltage when the system was turned off. Not good. Last night it was zero, now full pack voltage and dropping slowly, eventually getting into the millivolts range. It occurred to me that I was watching the capacitors in the DMOC drain which must mean that the contactors were still closed. Something awry with my precharge routine? I pulled the rear contactor and it checked fine.</span></div>
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<span style="font-family: Trebuchet MS, sans-serif;">Then I pulled the Better Place contactor module and found that the contactors were both locked in the closed position. Contacts welded shut! The GEVCU manual has a full chapter on precharge considerations, and my setup worked as it should last night. What happened?</span></div>
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<span style="font-family: Trebuchet MS, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvY0c_iT4LHYMEpw3oz_u2PNiZtwaDMIjHsUbSS1LofaowTncVaYHYEKapg5uTZFgDyUuh_PwtoDsvvoLQ8yMqiZqZBYcERqFf3e-cnKI-tk-4xrnxd2nGTUiKbvLsmAVGlP4MkRRvffc/s1600/IMG_4294.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvY0c_iT4LHYMEpw3oz_u2PNiZtwaDMIjHsUbSS1LofaowTncVaYHYEKapg5uTZFgDyUuh_PwtoDsvvoLQ8yMqiZqZBYcERqFf3e-cnKI-tk-4xrnxd2nGTUiKbvLsmAVGlP4MkRRvffc/s320/IMG_4294.jpg" width="200" /></a>Here's the culprit: sorry it's out of focus, but you can see the chunk of insulation that's missing. This is the common +12 volt connection for both contactors and the precharge relay. The GEVCU manages the startup sequence by opening first the precharge relay ground line, then the main contactor's ground after the capacitors have reached pack voltage, avoiding the inrush surge current that welds the contacts closed. What changed?</span></div>
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<span style="font-family: Trebuchet MS, sans-serif;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQBblUZ5m-ZPCFh9U1CUEs0px0jbEVtdoFzkYgBWxCZUNfTW9Yqs1n8XOs4YfxNi_GWtEX2YOwQJS3zrYBB9ZEM7sbn0fqHIoDOWOkqSon8MPdWM78eR2QWqQnWlumIfprp8Yw_ZkjqOw/s1600/IMG_4272.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQBblUZ5m-ZPCFh9U1CUEs0px0jbEVtdoFzkYgBWxCZUNfTW9Yqs1n8XOs4YfxNi_GWtEX2YOwQJS3zrYBB9ZEM7sbn0fqHIoDOWOkqSon8MPdWM78eR2QWqQnWlumIfprp8Yw_ZkjqOw/s400/IMG_4272.jpg" width="300" /></a>The yellow circle highlights the connection for the wire above. This particular wire was a bit too short to connect with the +12 volt terminals at the left of the box, so I connected it to the normal input side of the diode. Good +12v there, but a rather awkward placement - notice that it passes over the top of the output terminal on the charger side of the diode. I must have nicked the wire when I installed it, and then the bare wire made contact with the charger power output screw. When I plugged in the J1772, power passed through that screw to the contactors without the GEVCU managing the connection. Result: inrush current and welded contacts. I've ordered a fresh contactor, precharge relay and resistor. UPS should deliver them early next week, so all is not lost. Unless, of course, there is collateral damage to the GEVCU, but won't know that until later.</span></div>
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<span style="font-family: Trebuchet MS, sans-serif;"><i style="background-color: transparent;">For want of a nail the shoe was lost</i></span></div>
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<span style="font-family: Trebuchet MS, sans-serif;"><i style="background-color: transparent;">For want of a shoe the horse was lost.</i></span></div>
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<span style="font-family: Trebuchet MS, sans-serif;"><span style="background-color: #f9f9f9; color: #252525; font-family: sans-serif; line-height: 22px; text-align: center;"><i style="background-color: transparent;">For want of a horse the rider was lost.</i></span></span></div>
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<span style="font-family: Trebuchet MS, sans-serif;"><span style="background-color: #f9f9f9; color: #252525; font-family: sans-serif; line-height: 22px; text-align: center;"><i style="background-color: transparent;">For want of a rider the message was lost.</i></span></span></div>
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<i style="background-color: transparent;">For want of a message the battle was lost.</i></div>
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<i style="background-color: transparent;">For want of a battle the kingdom was lost.</i></div>
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<i style="background-color: transparent;">And all for the want of a horseshoe nail.</i></div>
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</span>Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0tag:blogger.com,1999:blog-7704297722315814760.post-13728350313387267292015-09-07T19:08:00.000-07:002015-09-07T19:14:35.672-07:00Circuit Box<span style="font-family: Trebuchet MS, sans-serif;">Three very long days in my 90+ degree garage have put the project ever closer to it's first test drive. </span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsI184btFQKfcRR492UxqUS8OVWcZKHhpUfEJXYhJW5Sc63FJKRKQky6FJrFHxwvOGj6E1iQogJum0M8OaR3cRDS4J4LKAG1z5Rr6H3mofeJn1bM8A3oMs1N3CT33emcBWIVd9SQ7Ad6I/s1600/IMG_4277.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsI184btFQKfcRR492UxqUS8OVWcZKHhpUfEJXYhJW5Sc63FJKRKQky6FJrFHxwvOGj6E1iQogJum0M8OaR3cRDS4J4LKAG1z5Rr6H3mofeJn1bM8A3oMs1N3CT33emcBWIVd9SQ7Ad6I/s640/IMG_4277.jpg" width="480" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif;">That tangle of wiring at the back of the inverter is finished save for one wire to the reverse switch. </span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje-3vDeeXlUNuG9IZ0golf1cNtBqZC4Ft2GdAoXYlgSbbZFwCHKJGYN4wauQhoXIt35qMkkvohE2G4DLzQ3CVjMQrB-E3tZRvvy7HY2kNbDQ2oq-YuKGs4Napr2EKXT-3yYCbKUPkqerU/s1600/IMG_4271.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje-3vDeeXlUNuG9IZ0golf1cNtBqZC4Ft2GdAoXYlgSbbZFwCHKJGYN4wauQhoXIt35qMkkvohE2G4DLzQ3CVjMQrB-E3tZRvvy7HY2kNbDQ2oq-YuKGs4Napr2EKXT-3yYCbKUPkqerU/s640/IMG_4271.jpg" width="480" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif;">It looks like total chaos, but there is a method to the madness. The relays (clockwise from the upper left) control the 12 volt switched ignition, power steering pump, heat exchanger fan, and charger. Almost invisible above the charger relay is a dual power diode that enables what I hope is a clever way of automating the charge process. I can't test that until the rear wiring is done (tomorrow, if all goes well), but in theory, it's very cunning. I have been able to test the power brake vacuum pump, power steering pump, and coolant pumps, and all are spot on! I do plan to put a cover on the circuit box so it looks neat and tidy.</span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfwwbA9y3VbmJGPVeM3hLvpv3lVaES0t8kkoRlLVYw7fGPKEcaEdSzTZFOHeFrA9TtOxHkMoU62KYwKYK8tN4HJ1Pm7ybBiWby8tHhTNZDfI95EEXRl2YC_kbe6GAlMEdG5idD2hyphenhyphenFSAU/s1600/IMG_4276.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfwwbA9y3VbmJGPVeM3hLvpv3lVaES0t8kkoRlLVYw7fGPKEcaEdSzTZFOHeFrA9TtOxHkMoU62KYwKYK8tN4HJ1Pm7ybBiWby8tHhTNZDfI95EEXRl2YC_kbe6GAlMEdG5idD2hyphenhyphenFSAU/s320/IMG_4276.jpg" width="320" /></a><span style="font-family: Trebuchet MS, sans-serif;">The vacuum pump has its own relay and wiring jumble. Yesterday I solved the mystery of how and where to hook up the vacuum lines to get the air conditioning flap to operate. Once it did, it moved an impressive amount of air, and will need to be somehow integrated with the aftermarket AC compressor. That's for another day.</span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioGqrF8oI-X3HV2QgaqibEXuVy5evNpgrkWZyZ1n-BwaJHXRwZfjaXaMuERvqyA_uXormdEoTkMjQte1ay08B2W_aEoUbkA0T6rNCLoG8NaeRtTkhWF2sz9qhhgWBumY0F0-9RdGa9id4/s1600/IMG_4274.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioGqrF8oI-X3HV2QgaqibEXuVy5evNpgrkWZyZ1n-BwaJHXRwZfjaXaMuERvqyA_uXormdEoTkMjQte1ay08B2W_aEoUbkA0T6rNCLoG8NaeRtTkhWF2sz9qhhgWBumY0F0-9RdGa9id4/s320/IMG_4274.jpg" width="320" /></a><span style="font-family: Trebuchet MS, sans-serif;">The 12 volt battery feeds an eighty amp breaker that serves all the EV circuitry and provides a single shut-off point. The 50 amp fuse on the left protects the power steering pump. With the battery pack cabling ahead tomorrow, along with the remainder of the charging support, we are closing in on a first test drive. Keep checking in ...</span></div>
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Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0tag:blogger.com,1999:blog-7704297722315814760.post-7212289883851247362015-09-04T18:51:00.001-07:002015-09-04T18:56:40.584-07:00Wiring the Motor Bay<span style="font-family: Trebuchet MS, sans-serif;">Spent the day routing wires and organizing the split loom to keep things neat and organized. Started by wiring the power steering pump and aggregating with the cooling pump wiring for a single loom into the circuit box.</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilQO92tHIhxXKPs5iA8O4SBhZaPqQRDO8FLAHjg2EQ41PaEA6xCttmndV7IfqiJDwEwLw-RYjAaW47wMwLoW2mWXI7sXfaahCPRhjhP99e4RrAf5gvLzu6U6crRW3q1MAtvPlMB_lBDdk/s1600/IMG_4265.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilQO92tHIhxXKPs5iA8O4SBhZaPqQRDO8FLAHjg2EQ41PaEA6xCttmndV7IfqiJDwEwLw-RYjAaW47wMwLoW2mWXI7sXfaahCPRhjhP99e4RrAf5gvLzu6U6crRW3q1MAtvPlMB_lBDdk/s640/IMG_4265.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj94nDiogwq5r23JS1cLom8-A2pYa4Cy4YnEgVA01-ukPmaw0MOt31Uzb61Nr1Q0mTZhuguAshK4ZmgQDIWnu3ltfaLJg61bJcwhWL7PEHzFDbA47KncIoSZScqhB49cMYrb0qV5dIXHUs/s1600/IMG_4266.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj94nDiogwq5r23JS1cLom8-A2pYa4Cy4YnEgVA01-ukPmaw0MOt31Uzb61Nr1Q0mTZhuguAshK4ZmgQDIWnu3ltfaLJg61bJcwhWL7PEHzFDbA47KncIoSZScqhB49cMYrb0qV5dIXHUs/s400/IMG_4266.jpg" width="300" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif;">After cutting the high voltage cable to size, I crimped on the lugs and installed the contactor module. </span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">The GEVCU is mounted to the rear of the inverter and excess cable is coiled on the coupler housing below it. Other wiring is tagged and ready to be connected to the GEVCU harness.</span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2YPpXPKq1hUALfGrh1HrOyWs88jPbtvGX6L-OziLGBRJZO4Rl3xMJ_VHhFNKqUSekze62kIGYrv_DaYWoc17VZxgPgazdpFKHp-UHjy-m1GdWXahowo6kY1AuzZMvYesQO3_cXu7PV7Q/s1600/IMG_4267.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2YPpXPKq1hUALfGrh1HrOyWs88jPbtvGX6L-OziLGBRJZO4Rl3xMJ_VHhFNKqUSekze62kIGYrv_DaYWoc17VZxgPgazdpFKHp-UHjy-m1GdWXahowo6kY1AuzZMvYesQO3_cXu7PV7Q/s400/IMG_4267.jpg" width="400" /></a></div>
<span style="font-family: Trebuchet MS, sans-serif;">The charge controller is mounted to the front of the inverter and all connected to the charger.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">The fan wiring is consolidated with the charger and throttle wiring, then routed to the back of the inverter where it will be fed with all the other connections into the circuit box.</span><br />
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Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0tag:blogger.com,1999:blog-7704297722315814760.post-38491666993092321692015-09-03T19:00:00.000-07:002015-09-04T18:57:50.049-07:00Meanwhile ...<span style="font-family: Trebuchet MS, sans-serif;">Robert has been painting up a storm. These all look great, and I'm afraid the rest of the car will need the same treatment down the road a bit.</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEij8xlwd0aihj-GJrNaxtSKTXQC63ZNk_m7cT-Zp9-38q_uwenoz2KBA-Ao24HQajPjrl_qRhYo4sVnOtTy9BpS0dS9owXNyKtryeODe_PePiKnYzp2r8fCXDfYscQn8f7kT8xpu1_jBiQ/s1600/IMG_4253.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEij8xlwd0aihj-GJrNaxtSKTXQC63ZNk_m7cT-Zp9-38q_uwenoz2KBA-Ao24HQajPjrl_qRhYo4sVnOtTy9BpS0dS9owXNyKtryeODe_PePiKnYzp2r8fCXDfYscQn8f7kT8xpu1_jBiQ/s320/IMG_4253.jpg" width="320" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif;">Robert mentioned that I really should get the headlight covers painted as well so they match. He's right, of course, so I pulled them off the car and took them over. The car will look fantastic!</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">Robert also finished out the top cover for the coupler housing, so I picked that up and spent nearly all morning installing it. It's in a very awkward place with no room to swing a wrench, so four bolts took way too long. It had to be done now because the GEVCU will be mounted over it and it will be even more obscured with all the cabling that goes along.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">The afternoon was spent on an equally fussy project, fabricating and installing the charge port. Again, working in the hatch behind the former gas filler is an exercise in contortion, but the payoff is a really pretty piece of bling.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">Along with those two major projects, I finished installing the GEVCU and Charge Controller now that the paint has dried on the mount box, and started gathering the under hood wiring into split looms for connection to the GEVCU harness in the circuit box. </span>Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0tag:blogger.com,1999:blog-7704297722315814760.post-70538488203364539042015-09-01T19:10:00.000-07:002015-09-02T06:14:15.843-07:00Building Better Boxes<span style="font-family: Trebuchet MS, sans-serif;">A couple of nights ago I woke up at 2:30am with a brilliant idea that came to me in a dream. OK, maybe not so brilliant, but gives you some idea about what I've been dreaming about lately. It actually made sense the next morning, and had nothing to do with Dilithium Crystals, Gigawatt Transformers, or Ancient Aliens.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">I have not been happy with the contactor box being in the rear of the car with the battery pack. I had already run high voltage wires through the passenger cabin along with the control wiring, which made me nervous. It just wasn't right.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">I had wasted the better part of two days trying to find a space in the motor bay, but they were either too low and subject to water splash, or too precariously fragile. </span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiw4yTsDKiR2S0stLgdaWtKkTHkxBUS43MFIpAv1CJmzUbGpGizG_t9Epfy2BTnjakHhY2oq4BMgwMe2idzVFCzkZW9STP4TYSGWVc5zTMBUV4timNb1rAGGZnWtSGT8Ov82KhS-4INf4o/s1600/IMG_4246.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiw4yTsDKiR2S0stLgdaWtKkTHkxBUS43MFIpAv1CJmzUbGpGizG_t9Epfy2BTnjakHhY2oq4BMgwMe2idzVFCzkZW9STP4TYSGWVc5zTMBUV4timNb1rAGGZnWtSGT8Ov82KhS-4INf4o/s320/IMG_4246.jpg" width="320" /></a><span style="font-family: Trebuchet MS, sans-serif;">Here's the dream: </span><span style="font-family: 'Trebuchet MS', sans-serif;">(In the voice of Charlton Heston) </span><span style="font-family: 'Trebuchet MS', sans-serif;">Build ye a box around the inverter, and behold thy contactor module may be affixed thereto. Yea, verily I did proceed to do just that, using pressure treated exterior 5/8" plywood that was left over from the evTD project. Some scrap aluminum angle and a treaded rod to hold it all in place, and that's the box. With some T-nuts and three bolts, it's a comfortable fit in the space between the inverter and the coolant catch tanks with all the plumbing below.</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUyCEWLCTkFYSkIdh5pdzVV6SHhZQ1Xn9Lh-Fhlecq8kA03lc213YM1294hGVlWsX-xqk7FPsloBbiPtzobwjQuspRnbTZU2oVKmyNqlaAPaqAJt-gNLg2VrwufKMhdZoZOYPMxucVYL4/s1600/IMG_4250.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUyCEWLCTkFYSkIdh5pdzVV6SHhZQ1Xn9Lh-Fhlecq8kA03lc213YM1294hGVlWsX-xqk7FPsloBbiPtzobwjQuspRnbTZU2oVKmyNqlaAPaqAJt-gNLg2VrwufKMhdZoZOYPMxucVYL4/s320/IMG_4250.jpg" width="320" /></a><span style="font-family: Trebuchet MS, sans-serif;">The contactor module was included with the Better Place battery pack and contains the positive and negative contactors</span> <span style="font-family: Trebuchet MS, sans-serif;">along with the precharge resistor and control relay, all nicely integrated. It has the connections for the high voltage wiring from the battery pack and output connections for the inverter.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">The front of the box will mount the charger controller and the <a href="http://store.evtv.me/proddetail.php?prod=gevcu" target="_blank">GEVCU</a> system controller will mount on the back. The GEVCU manages a whole range of car functions in addition to the motor speed control, and needs a way to connect a bunch of wires in some orderly way.</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIG2bVVfAeZqpS7P9iCzE0IWXJz0yMTkt5CGXMMtQB7qiA5Doxk2E4_03Ee_lpu4EKaev9l4CXyHZTWat4UrNGaxz5-aPqneFTLpwGwYkV7pnR1W-cd9I6DbgO1RlpadRToVu1ADwo9bw/s1600/IMG_4245.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIG2bVVfAeZqpS7P9iCzE0IWXJz0yMTkt5CGXMMtQB7qiA5Doxk2E4_03Ee_lpu4EKaev9l4CXyHZTWat4UrNGaxz5-aPqneFTLpwGwYkV7pnR1W-cd9I6DbgO1RlpadRToVu1ADwo9bw/s320/IMG_4245.jpg" width="320" /></a><span style="font-family: Trebuchet MS, sans-serif;">I had spent hours laying on my back under the dashboard in a contortionist pose that would would make Cirque de Soleil proud. I found and removed what Porsche calls the "Digital Motor Electronic Control Unit". Just as I suspected, once it was disconnected, the basket of snakes under the hood slithered off. All that messy wiring was there to feed sensor information about the gas motor to the ECU so it could fiddle the timing and fuel injection. After hours of searching, I finally found the switched 12 volt wire, a single wire among the seven bundled into the cruise control harness. With all of that gone, the motor bay is a much neater place.</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg2EKSVFWFSUYcmTe8iztgmJ_ryMMKNmOLp_a8oqWbGFKf3s9VaCbg91sMdkigD69C_2BKE47Ek7_lK_CJjH0Du35gPIIIGYP7o0yUioShIdDNWynGz5k2niNp_Rc4996Iih9Ox0Fqkye4/s1600/IMG_4251.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg2EKSVFWFSUYcmTe8iztgmJ_ryMMKNmOLp_a8oqWbGFKf3s9VaCbg91sMdkigD69C_2BKE47Ek7_lK_CJjH0Du35gPIIIGYP7o0yUioShIdDNWynGz5k2niNp_Rc4996Iih9Ox0Fqkye4/s320/IMG_4251.jpg" width="320" /></a><span style="font-family: Trebuchet MS, sans-serif;">So now the electric motor needs the same sort of inputs and outputs, so a circuit box was built and mounted on the top rear of the inverter. Four relays and twenty six terminal connections will be centrally housed here with all wiring entering and exiting through the open back. I think I'll put a hinged lid on it for easy access later.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">A coat of black paint will make the whole apparatus disappear, then I can mount the components and wire everything up. That should basically finish the under-hood activity and we'll move on to the back. Tomorrow is another day ...</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgt0jma1M0lh1J5wrlhcYdL4MzI6xoRM3Q5wx16k-6xg4r1PRzII57v_fBu-x40_i6ZW7GctGYY7fsj915LLcWlQfxuNUxmKPt17ivRB3qsnHSQ_hCGeI6GUu2DPIlfyItWg3FIssc6nkw/s1600/IMG_4215.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgt0jma1M0lh1J5wrlhcYdL4MzI6xoRM3Q5wx16k-6xg4r1PRzII57v_fBu-x40_i6ZW7GctGYY7fsj915LLcWlQfxuNUxmKPt17ivRB3qsnHSQ_hCGeI6GUu2DPIlfyItWg3FIssc6nkw/s320/IMG_4215.jpg" width="240" /></a></div>
<span style="font-family: Trebuchet MS, sans-serif;">Remember that perfect spot I found for the high voltage fuses a couple of days ago? It had a couple of threaded openings in the strut mount, easy access and clearly designed for the fuses, right?</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">Well, turns out it was also the perfect spot to mount the throttle. It was right in line with the accelerator cable and just the right distance away. It allowed a gentle angle for the cable and once in place, very good feel for the pedal.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">I'm once again using the <a href="http://store.evtv.me/proddetail.php?prod=throttlepot" target="_blank">Evnetics Throttle Pot</a>. I used it on the eBugeye and the evTD. It has been bulletproof and easy to set up using the existing pedal and cable. Unfortunately, Evnetics has moved on to other markets, so this may be my last one.</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNBKF0GWVI3o2Ksc7_fAbyUap6tpqFHXA5jGi_6vQU_QYci2-YdN-eQePnsvJPATvRJE3b_prltEW1zZ_sT4UEpTMkLMtp-7OBGQeQGe73gko3Q1_aSbYSinttwPDRXVvPoWJBplPyY44/s1600/IMG_4240.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNBKF0GWVI3o2Ksc7_fAbyUap6tpqFHXA5jGi_6vQU_QYci2-YdN-eQePnsvJPATvRJE3b_prltEW1zZ_sT4UEpTMkLMtp-7OBGQeQGe73gko3Q1_aSbYSinttwPDRXVvPoWJBplPyY44/s640/IMG_4240.jpg" width="640" /></a><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjf7CIrCdyLcYhcYZoRePH5lWedgusHU0_FzHYtSU7IVy1NSX4ELcN6ijiB4rSVs1I1M3HXt5Sx_QgsJG33_OPt0t1Ij-p6v4yERX9DvEFCBSK_6AgDvJVVQXv5uO5MqZeS4whNmxSnUE/s1600/IMG_4241.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjf7CIrCdyLcYhcYZoRePH5lWedgusHU0_FzHYtSU7IVy1NSX4ELcN6ijiB4rSVs1I1M3HXt5Sx_QgsJG33_OPt0t1Ij-p6v4yERX9DvEFCBSK_6AgDvJVVQXv5uO5MqZeS4whNmxSnUE/s320/IMG_4241.jpg" width="240" /></a><span style="font-family: 'Trebuchet MS', sans-serif;">Working around the aluminum mounting plate, I snagged a finger on the sharp edge (ouch) so I added some door edge guard strips to make it "finger safe". Makes the whole installation look pretty neat.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">So what to do with the fuse mount that got displaced? Found another perfect spot for it with another threaded opening, this time on the frame rail. I had to employ the "wire stretcher" since the new mounting point is a bit father away from the firewall. It looks like it was designed for the spot as well with the added bonus that it's within easy reach of the charger cable. The other fuse will attach to the air conditioner positive cable. I used fairly stiff 6 gauge wires to span the distance to the battery pack under the hatch and the high voltage wires from the charger and A/C compressor appear to be 10 gauge, so once again, overkill is always appropriate.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;"><br /></span>Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0tag:blogger.com,1999:blog-7704297722315814760.post-7413198072568924592015-08-27T18:42:00.000-07:002015-08-27T18:55:00.004-07:00Cool, Man!<span style="font-family: Trebuchet MS, sans-serif;">The cooling system is complete. The plumbing is a hybrid of 3/4" heater hose and elbow fittings to connect the catch tanks, pumps, motor, and inverter, 5/8" heater hose for the charger with 3/4 to 5/8 adapters, and AN8 hose and fittings to and from the heat exchanger.</span><br />
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<span style="font-family: Trebuchet MS, sans-serif;">Starting with the forward pump, there's an elbow to get the hose pointed at the charger and a 3/4 to 5/8 step down to get the correct size.</span><br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzVufWwy3C4mR2zb6BUiJ9zm23-np1fbyIXBfDrnlUiTZJWs73P0edqY7oXCggtHJZNwNh58_Tcr_X_gQEIuJMWu8Bez0qh0uU3a3yyrLKUb3BO4mZLkKwVE3bOKYKR4hyphenhyphenkpLwteHrnHY/s1600/IMG_4225.jpg" imageanchor="1" style="clear: right; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzVufWwy3C4mR2zb6BUiJ9zm23-np1fbyIXBfDrnlUiTZJWs73P0edqY7oXCggtHJZNwNh58_Tcr_X_gQEIuJMWu8Bez0qh0uU3a3yyrLKUb3BO4mZLkKwVE3bOKYKR4hyphenhyphenkpLwteHrnHY/s400/IMG_4225.jpg" width="400" /></a></td></tr>
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<span style="font-family: Trebuchet MS, sans-serif; font-size: small;">looping through another 3/4 - 5/8 step up sleeve and elbow into the motor inlet. </span></div>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg111DHBk1TCyPLn3JvnIzM4Xz8nW1jnElXnZdQf00CTKuBoD8r8ALnrwVWc6gi5MtJJaOt-7isee6jvR_PzFGhPy1gK5P210Lr3u3o5tWpJrSm4OP-tk9pzPlo_LuJ3EXBdDlUT_HZH-0/s1600/IMG_4233.jpg" imageanchor="1" style="clear: right; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg111DHBk1TCyPLn3JvnIzM4Xz8nW1jnElXnZdQf00CTKuBoD8r8ALnrwVWc6gi5MtJJaOt-7isee6jvR_PzFGhPy1gK5P210Lr3u3o5tWpJrSm4OP-tk9pzPlo_LuJ3EXBdDlUT_HZH-0/s400/IMG_4233.jpg" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;"><span style="font-family: Trebuchet MS, sans-serif; font-size: small; text-align: start;">the motor outlet leads to an AN8 adapter</span></td></tr>
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<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_NGCQh-6IgOkSTjzPBL8XD7pQ4h_RXY9D-sF85TYs7LV_SvR_yJEZF9Hzp8RuXNNNG_Fc9pE-bwrhrqJJRb7IHJK4nwXp2owowXH5eNqJ5utecypxhyphenhyphen8DxDkkp9zgMpnKkXviRb2tu4U/s1600/IMG_4227.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_NGCQh-6IgOkSTjzPBL8XD7pQ4h_RXY9D-sF85TYs7LV_SvR_yJEZF9Hzp8RuXNNNG_Fc9pE-bwrhrqJJRb7IHJK4nwXp2owowXH5eNqJ5utecypxhyphenhyphen8DxDkkp9zgMpnKkXviRb2tu4U/s400/IMG_4227.jpg" width="400" /></a></td></tr>
<tr><td class="tr-caption"><span style="font-family: Trebuchet MS, sans-serif; font-size: xx-small; text-align: start;"><span style="font-family: Trebuchet MS, sans-serif; font-size: small;">that connects to the heat exchanger</span>.</span></td></tr>
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<span style="font-family: Trebuchet MS, sans-serif;">The heat exchanger is a dual core Derale unit with the upper core serving the motor and charger cooling loop and the lower core taking care of the DMOC inverter. The inverter had to be removed to install the plumbing on the front of the motor.</span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKhKcft8XeoAg8sf4BRLhjbpTWjAis1sy2oDP0Zzn6mBP_zKqwBeKcykh6_f9aOj1kM4sHWc_Tmz38pbtWpwwpi8R9S2zbBlYXw9lFAlQ661AgrHsepJl8RUFh3gAmk9b3x0uv4vCVz-I/s1600/IMG_4234.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKhKcft8XeoAg8sf4BRLhjbpTWjAis1sy2oDP0Zzn6mBP_zKqwBeKcykh6_f9aOj1kM4sHWc_Tmz38pbtWpwwpi8R9S2zbBlYXw9lFAlQ661AgrHsepJl8RUFh3gAmk9b3x0uv4vCVz-I/s400/IMG_4234.jpg" width="400" /></a><span style="font-family: Trebuchet MS, sans-serif;">While the inverter was out, I decided to rotate it 180 degrees to get the plumbing connections on the same side as the pumps, primarily to free up space on the opposite side for the air conditioning compressor fittings. You'll see soon why that was necessary.</span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8vEZDKhQqvZAI_AMKcKGwjuKuB8_aJ24NT1jkdd8Tbmm2WjrSUjkLlQoDnq_n3LJ_MI8AkTdjTpkXnVe8qKIKoAtl_d-Gtsr4QM8a5rKOxfcCh6xwrFusM7BdFxk5_rLOwH-hzi1nPKI/s1600/IMG_4235.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="200" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8vEZDKhQqvZAI_AMKcKGwjuKuB8_aJ24NT1jkdd8Tbmm2WjrSUjkLlQoDnq_n3LJ_MI8AkTdjTpkXnVe8qKIKoAtl_d-Gtsr4QM8a5rKOxfcCh6xwrFusM7BdFxk5_rLOwH-hzi1nPKI/s200/IMG_4235.jpg" width="150" /></a><span style="font-family: Trebuchet MS, sans-serif;">Unfortunately, that meant I had to chop up the artistically curved underside of the mount to get clearance for the protrusion on the bottom of the inverter. My grinder skills pale in comparison the Robert's, but what it lacks in grace and beauty, it makes up for in utility. The good news is that after the inverter is connected to the motor and secured, the mount will be out of sight.</span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHnMGH1L4uqTfz21kJxE6dLiwNjgjH21ZezZ63JCCrm2CBnO5ES_rr5eVXKiXTApiqu9VYpgXAbk3gTcanPWkDd3s1WuRnoisXY87Cie-7RNkgY_AD__Kqg0tQPD7mDwdpKGM9LOpJcWM/s1600/IMG_4237.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHnMGH1L4uqTfz21kJxE6dLiwNjgjH21ZezZ63JCCrm2CBnO5ES_rr5eVXKiXTApiqu9VYpgXAbk3gTcanPWkDd3s1WuRnoisXY87Cie-7RNkgY_AD__Kqg0tQPD7mDwdpKGM9LOpJcWM/s400/IMG_4237.jpg" width="300" /></a></div>
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<span style="font-family: Trebuchet MS, sans-serif;">With the inverter and its cooling loop installed, you can see that if the inverter inlet and outlet had remained on the opposite corner, it would certainly have left no space for the A/C fittings. As it is, it leaves scant clearance for the power steering pump. If it seems that there an awful lot of hose clamps, there are! The cooling system used twenty five clamps in addition to the ten I also installed today on the power brake vacuum lines.</span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5997gPaKVFotaLSimQtZPHd0269-dBaVQpAUNewPf0jRkYg6_VvCiku9x3sitLa_hSKvm0NrDpSaep_cf7cfQY5DjJc2YdjtiOVNUV18XqTp2OKKb9hnonVfSZgB_AFUkleFmILpGhbE/s1600/IMG_4236.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5997gPaKVFotaLSimQtZPHd0269-dBaVQpAUNewPf0jRkYg6_VvCiku9x3sitLa_hSKvm0NrDpSaep_cf7cfQY5DjJc2YdjtiOVNUV18XqTp2OKKb9hnonVfSZgB_AFUkleFmILpGhbE/s320/IMG_4236.jpg" width="240" /></a><span style="font-family: Trebuchet MS, sans-serif;">I set up my test rig to make sure all those clamps were doing their job. Good news - no leaks!</span></div>
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<span style="font-family: Trebuchet MS, sans-serif;">The systems took almost a gallon of coolant, and after about a ten minute run, all the air bubbles seemed to have worked their way out. I was most pleased that the time I spent last month <a href="http://porscheev.blogspot.com/2015/07/go-with-flow.html" target="_blank">calibrating the PWM signal generators</a> paid off. Those <a href="http://porscheev.blogspot.com/2015/07/pump-testing.html" target="_blank">tiny controllers</a> held their settings and ran the pumps at about half speed in near total silence. I've since learned that the pins exactly match a three pin computer fan cable. That will make for an elegant installation that, again, no one will ever see.</span></div>
Fred Behninghttp://www.blogger.com/profile/13519100383417732149noreply@blogger.com0