DIY ESS - AC Charger terminals modification for Water Heater

Before moving all the ESS components to the metal cabinet, I decided to make a last modification to the charger side relay and AC terminals; Instead of having 6 relays for 6 chargers, I removed the 6th one AC wires and left the relay terminal free for my water heater command line (220V, 2A max) that activates the coil of a 220V 20A line that feed the water heater at night during off-peak hours. A signal sent by the utility closes a relay in my utility meter at night and opens it in the morning, and this is how the water heater runs only on low rate electricity. Closing the 6th relay on the same command line, I will be able to switch ON or OFF the water heater as a "6th charger" in a way, meaning, when all the chargers from 1 to 5 will have been switched ON already

If you get my kit, have no water heater - or a gas one, like many in the USA - , use the 6th relay for a charger - like I used too all this time - continuing the AC charger line up to relay 6, the behaviour of the 6th relay has not been changed at all, it is still the 6th charger from teh Arduino point of view !

Then I add to move two chargers on the same AC terminal/ relay twice, like you can see on the photo since I have 7 chargers

I also changed the program so that when the 5th charger comes ON, and the arduino sees that it uses too much power compared to the net power, instead of switching it back OFF, it switches the 1st charger OFF instead, making it more precise (so always install several chargers on the same line towards the end: 4th, 5th)

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Here, all the cables have been replaced by 35mm2 ones; 2 mores: 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

EVTV Friday Show - March 22, 2013

- Progress on our Electric VW Thing and Jeff Southern's Electric VW Thing

- VW Transmission Adapter for Siemens Motor

- Silicone Rubber "Cell Booties" to protect exposed battery terminals 

News

Progress on Jeff Southern's Electric VW Thing

Progress on our Electric VW Thing 

VW Transmission Adapter for Siemens Motor

Speedster Nippon is almost complete

After several months of testing, Jack is showing his NEW Silicone Rubber "Cell Booties" to protect exposed battery terminals, a must have ! to easily & quickly protect your battery terminals  

Death of an EVCON participant ...