EV car conversion hardware

[muehlpower]

I have a similar problem, I need longer cables on the motor. My 70mm² cable has a larger outer diameter than the AWG 2/0. I will make stainless steel parts to make it fit.

[tom91]

I am also working on some adapters that we hope to sell at Zero-EV. Utilising gland components to work with 70mm2 or 50mm2 shielded cables.

[Hank]

Just got confirmation from Zero-EV that they expect to have these available in the next couple of weeks.
I'm on the notification list, very excited about this. Thanks @Tom91, appreciate it!

[arber333]

I have found an alternative for brake vacuum switch. It is variable. Anyone knows about that?
It looks robust enough... https://eveurope.eu/en/product/vacuum-switch/

[muehlpower]

I have one here but I haven't tested it yet. It is a MA-TER XV600. I bought it here for € 27.50:

https://www.ebay.de/itm/382775703794

you can buy it also at conrad electronic:
rubbercab Bestell-Nr.:583807
switch Bestell-Nr.: 583795

[arber333]

I have one here but I haven't tested it yet. It is a MA-TER XV600. I bought it here for € 27.50:

https://www.ebay.de/itm/382775703794

you can buy it also at conrad electronic:
rubbercab Bestell-Nr.:583807
switch Bestell-Nr.: 583795

OK, i see they have also a rubber cap to protect against moisture. Nice inclusion.
https://www.conrad.si/gumijasta-zascitn ... 0090-mater

I will order and test one piece. I will change standard 3/8 T fitting to accept 1/4 connection. My booster tube is for 3/8in adapter.

[arber333]

Hi everyone, and JackBauer...

Can anyone please post here where to get the fancy VCM casing with multiple AMP connectors front header?

I would like to know which case to use for Leaf VCM and with which connector header.

Also which wire connectors go with the header?

I cant seem to find any reference to that.
Maybe i am just not looking hard enough...

tnx

Arber

[tom91]

Hi everyone, and JackBauer...

Can anyone please post here where to get the fancy VCM casing with multiple AMP connectors front header?

Maybe i am just not looking hard enough...

Cinch enclosures : https://www.mouser.co.uk/new/cinch/cinch-modice/

TE Deutsch enclosures : https://www.te.com/usa-en/products/conn ... =pgp-story

[arber333]

Cinch enclosures : https://www.mouser.co.uk/new/cinch/cinch-modice/

TE Deutsch enclosures : https://www.te.com/usa-en/products/conn ... =pgp-story

OK, i think i am close. On Leaf board i see 20pin and 12pin header. I see one header that i can fit, maybe.

I found this header: https://www.newark.com/cinch-connectivi ... p/12AC5392

And this enclosure: https://www.newark.com/cinch-connectivi ... dp/53W2507

Would that be the one for Leav VCU, or Chademo VCU?

[Jack Bauer]

Just look at the boms on the Leaf and Gs450h github repos.

[Kevin Sharpe]

I'm not super happy with the stock HV cables for the LDU from Tesla, and am considering building my own bespoke cables, but there are some bit's I don't know how to source, or even what they are called. They are the connectors/Shielding terminators in the attached photos.

I couldn't find anything and decided not to wait any longer

viewtopic.php?f=11&t=37&p=15806#p15806

[Kevin Sharpe]

So I need to attache them back?

If you run a contactor that requires an economizer without one then you'll burn out the coil.

We had the Tesla Model S/X contactors on the bench this week. I can confirm they consume ~2.5A @ 13V and get very hot. They require an economizer.

[JaniK]

So to test if you need economiser on random contactor, just run it for a while on the table and check if its hot?
And check amps.

Is it that easy?

[tom91]

So to test if you need economiser on random contactor, just run it for a while on the table and check if its hot?
And check amps.

Is it that easy?

Any contactor drawing anything more then 1 amp usually will run hot, so thats the first tale tell sign.

[JaniK]

So to test if you need economiser on random contactor, just run it for a while on the table and check if its hot?
And check amps.

Is it that easy?

Any contactor drawing anything more then 1 amp usually will run hot, so thats the first tale tell sign.

Went ahead and tested Ford Focus Electric 23kWh contactors.
Main HVBAT+ TE 2098952-2

It Will disconnect at 1.2V0.3A
Reconnect happens at 6.6V1.56A
Draws 2.7amps at 11v stepping down from 12V el-cheapo.

When adjusting the voltage down to point where current is 1A, it will take 4.2v

Charge/precharge contactors TE 2138551-3 draw
0,7A@12V
0,35A@6V
Cutoff 0,16A@2.8V
Cutin 0,28A@4.8V


Measured with a DIY adjustable 1-12V power supply made with about second cheapest semi ready parts on ebay, so not the most accurate but still wanted to share.

[Cookie6000]

I had this in my thread but I thought I would add it in here to the Hardware thread. DC/DC converter I am using is the TDK unit from the AZD Transit Connect conversions. I gathered a lot of the info from various locations including from lars rengersen who fitted one to his Amazon.

100A water cooled (I did read somewhere that it was 80A if air cooled, tbc).The control pins:
Pin 1 is to disable. Pulling the enable pin to ground, turns off the power supply. Good direction from Lars here was to enable Pin 1 only after precharge is complete as you want the precharge energy to go do the inverter capacitors and nothing else. I actually tried this out inadvertently earlier and sure enough, the main connector wont close if the DC/DC is operating.
Pin 3 controls the output voltage. Not connected it is 14.5v. Pulled to ground is 13.8v.
Pin 6 is a fault pin. Not connected and have not found anyone who uses it yet.
The connector can be found on Alibaba - 90980-11658 10 hole Transmission solenoid valve plug for TOYOTA
http://www.kinkong-connector.com/produc ... ID898.html

More info here on the unit.
https://www.diyelectriccar.com/threads/ ... ter.91682/

[Doig5710]

Hey looks like a good DC-DC option just wondering if there was a part number to google/search for?

[jcwright45]

Anyone have any recommendations for water based cabin heaters besides the Nissan Leaf version? I don't want to rip out my dashboard to install a matrix unit if I don't have to. Looking for something already hacked, tested, and possibly on the inexpensive side.

[bobby_come_lately]

Anyone have any recommendations for water based cabin heaters besides the Nissan Leaf version? I don't want to rip out my dashboard to install a matrix unit if I don't have to. Looking for something already hacked, tested, and possibly on the inexpensive side.

Can't offer you tested but I am worked on modifying a cheap engine pre-heater from AC to DC. Notionally 2kw. Like this one, but only cost me about £20-25 (Chinese site I think - Aliexpress maybe?) https://www.ebay.co.uk/itm/2kw-Engine-C ... 1955251248.

Has 19mm barbs. Opened it up and disconnected the motor then removed the rotor and impeller and filled the gap with high temperature silicone. Planning to use it with one of the cheap VAG-clone pumps as a test.

[Cookie6000]

Hey looks like a good DC-DC option just wondering if there was a part number to google/search for?

Ah, sorry. I forgot to add in the vital piece. the TDK 9M68 14B227 AB. Here is the label

[Hank]

I am also working on some adapters that we hope to sell at Zero-EV. Utilising gland components to work with 70mm2 or 50mm2 shielded cables.

Did you ever get those made?

[tom91]

Did you ever get those made?

Getting close now, we have some samples made. However finding the right grounding springs and gland items is proving a bit of a pain. So probably ending up making everything bespoke.

[mdrobnak]

Hey looks like a good DC-DC option just wondering if there was a part number to google/search for?

Ah, sorry. I forgot to add in the vital piece. the TDK 9M68 14B227 AB. Here is the label
20200925_085839.jpg

TDK - Not exactly making cassette tapes any more! Wow. Definitely an unexpected branch name to see.

[arber333]

TDK - Not exactly making cassette tapes any more! Wow. Definitely an unexpected branch name to see.

Ya, TDK be making a lot of electronics, it is just diversified so you dont exactly know which division works on that . Even Volt gen1 DCDC is made by them.

[DarkwingDuck]

Hey looks like a good DC-DC option just wondering if there was a part number to google/search for?

Ah, sorry. I forgot to add in the vital piece. the TDK 9M68 14B227 AB. Here is the label
20200925_085839.jpg

I just bought the ford escape hybrid version, 8M68 14B227 AB, supposedly rated for 210-397V HVDC and with 1,5 kW max output(?). I'll try it out later and report the results here