EVTV Friday Show - March 28, 2014

- Karman Ghia update

- New battery straps for Nissan Leaf cells

- New test benches and inverters on their way

- Basic terminal and cable assembly

LiFePO4 ESS - Crimping again - 35mm2 cables

Let's crimp again !  :-)

This sunday, I cut & crimped 35mm2 cables to replace the small doubled ones that could not hold high current too long ...

Now this is much better 

35mm2 copper cable into 35mm2 / 8mm lug

screwed onto the GTI side Tyco Kilovac contactor

and onto the postivie battery pack terminal

First link from the battery pack to the contactor : Done

Since I could not find any red 35mm2 cable, I just put some red tape on both ends to mark it "RED"

Here, all the cables have been replaced by 35mm2 ones; 2 mores: 

- From battery pack negative terminal to the GTI stack negative terminal

- From GTI side Tyco Kilovac contactor to the GTI stack positive terminal

Now I can put the GTI stcak and the chargers at a 1.5m distance from the battery pack and ESS Control Board / EMS - Energy Management System - ; I am planning on putting all these just outside the window to be able to charge at night - low rate - and sleep normaly - all this is in my bedroom :-) - 

GTI side Tyoc Kilovac contactor

GTI stack

Battery pack terminals

LiFePO4 ESS Battery pack

DIY ESS - Crimping of the 10mm2 cable for the charger side

Easter monday crimping & soldering fun

This 10mm² cable will link the chargers and the battery pack negative terminals, through this 6mm bolt 

I added some heat shrink this time

The small lugs are soldered on each charger leads, 8mm for positive ones, 6mm for negative ones 

8mm ones will all go to the Tyco Kilovac EV200A1ANA (the new one with home made economizer) and the 6mm ones will go the the bolt, connecting to the negative battery pack terminal