Power in Flux

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    Unmounted the motor from the chassis but kept it...

    Unmounted the motor from the chassis but kept it connected to the controller, one last ground loop confirmed! The glitching went away with the motor pulled from the frame and controller powered up.
    ...
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    Powered things up and much improved but still a...

    Powered things up and much improved but still a little glitchy with the relays controlling the accessories.

    After a little more investigation it looks like floating inputs on the Arduino. I have...
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    OK.. so far here's all the ground loops I've been...

    OK.. so far here's all the ground loops I've been able to isolate. :D I still have a weak one back at the drive motor even though I put isolating washers/sleeves at the bolts on the motor face. I...
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    Progress. Snooped inside the headlight housings...

    Progress. Snooped inside the headlight housings (metal) and saw that the park/turn lamp socket assembly is screwed directly to the housing and has the ground wire attached at one of the screws....
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    The lights are controlled by a commercially...

    The lights are controlled by a commercially available LED module manufactured by Penta-Star. The inputs are 12V normally tapped directly from switched lighting circuits, and they also provide the...
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    Still sorting through things here. So far have...

    Still sorting through things here. So far have swapped out a 2-pole relay for a 3-pole relay on the AC Mains input power for the Thunderstruck charger so I can completely isolate it (and its ground)...
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    Measuring 50kOhm+ from the case of both the...

    Measuring 50kOhm+ from the case of both the charger and the Curtis, to nearby points on the carbon chassis so looks like there is a path through the mounts. Easy enough to fix with a reciprocating...
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    OK, I will double check that. The chassis is all...

    OK, I will double check that. The chassis is all carbon fiber so it won't conduct very well, but I still used fiberglass or plastic enclosures at the 12V distribution points for safety. The mounting...
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    Under the Main Contactor Menu in the programmer,...

    Under the Main Contactor Menu in the programmer, I set the MAIN_ENABLE parameter to OFF and then cycle power to the controller so it turns on but doesnt close the contactor. This way I can take the...
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    I checked the dimensions on the Sevcon DC-DCs, I...

    I checked the dimensions on the Sevcon DC-DCs, I definitely have room for two. :)

    Did a little more testing today. This time I turned off the PWM driver for the main contactor to see if it's...
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    Alright, making some headway I think. Went...

    Alright, making some headway I think.

    Went out to take some more resistance measurements and at first I was stumped because the numbers kept changing and were literally all over the map. Every...
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    Correct. Yes. OK. I can also try...

    Correct.



    Yes.



    OK. I can also try disconnecting the DC-DC from the system to see if that isolates the issue.
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    Yes, the CANOP is the opto isolator for the CAN....

    Yes, the CANOP is the opto isolator for the CAN.

    RE: the diode, the idea was to add a switched bypass around that diode to allow control of the charging of that battery. The more I think about it...
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    Thanks Travis, will measure and see what I find...

    Thanks Travis, will measure and see what I find out.

    In the meantime, here's a wiring diagram. It's not 100% complete as I haven't added all the connections at the front of the vehicle nor the...
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    It's a SD-500H-12 Also have an on-board...

    It's a SD-500H-12

    Also have an on-board Thunderstruck charger connected to the 96V side, with the EVCC on the 12V side and CAN bus between them.
    Also using an Orion BMS which closes the 12V...
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    I'm using a Mean Well 500W DC/DC converter....

    I'm using a Mean Well 500W DC/DC converter. However this issue is happening whether that unit is powered or not.

    I'll put some more time and detail into the wiring diagram.

    The Arduino/Relay...
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    Noise issue related to Curtis 1238

    Currently having an issue with what I'd guess are particularly sensitive electronic items picking up noise.

    I have an Arduino controlled relay module that I built, which switches a few circuits...
  18. Thanks guys! I have no option but to finish, I'm...

    Thanks guys! I have no option but to finish, I'm waaaaaay too far into it to quit! :D

    It's been testing me lately though. Literally only hours worth of actual work to get it on the road for the...
  19. Slooooooowly but surely getting there.... all the...

    Slooooooowly but surely getting there.... all the high voltage side is installed and tests out OK.. got a gremlin somewhere in the CAN bus now that was not there when I first tested the charging...
  20. Thanks guys! Here's a couple of the most recent...

    Thanks guys! Here's a couple of the most recent work, on the rear of the cabin.


    ...
  21. Shaping the rear section. I decided to make this...

    Shaping the rear section. I decided to make this part more of a deck instead of trying to blend the roofline down into it. I couldn't figure out how to blend and keep it looking cool, plus this...
  22. Down and dirty roughing out the front end of the...

    Down and dirty roughing out the front end of the body.

    ...
  23. Shaped the dashboard using the interlocking floor...

    Shaped the dashboard using the interlocking floor mats and lots of hot glue. :) This foam is great for shaping contours because it cuts easy, holds its shape well over unsupported spans, but when you...
  24. Center console and floor in the works. The...

    Center console and floor in the works. The square-ish shape at the bottom of the console will be obscured by the seats so I did not put much time into sculpting a lot of shape into it, plus I...
  25. First a couple overall shots of the rolling...

    First a couple overall shots of the rolling chassis

    **edit** gah sorry about them being upside down, thats not how they're showing on my screen, LOL.

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