Fault finding help

[iain85]

Hi Alex,

Just ordering the bits you suggested and when I got to the inline fuse the one you linked it said max 32v. Is this the one you used and will it be ok for my 36v battery?

Thanks,

As d8veh says you can just cut off the phase bullet connectors and splice the wires together. Much easier than soldering on to PCB.

I'm not sure on the button but it seems a good idea to use it as a throttle signal interruptor. I guess you'd need to splice the throttle wires over it somehow if it is basically a momentary switch but I'm not sure exactly how .. maybe Dave can work that one out as it would be a neat solution.

These powerpoles are fine for your battery power supply to controller interface :

10 X ANDERSON POWERPOLE 45 AMP ELECTRICAL CONNECTOR PLUG, GOLF TROLLEY, KIT CAR | eBay

The contacts crimp but there is an insertion tool to get the contacts into the connectors :

INSERTION/EXTRACTION TOOL FOR 30AMP & 45AMP ANDERSON POWERPOLE CONTACTS | eBay

It saves some cursing, patience and fiddling with multimeter probes to push them home but for only a few you can also manage without.

If you are changing them why not fit an inline fuse at the same time :

1 x SPLASHPROOF INLINE 40amp RATING STANDARD BLADE FUSE HOLDER ATO CAR AUTO | eBay

You can see one installed on the bottom photo of my battery here :

http://www.pedelecs.co.uk/forum/uk-off-road-s-pedelecs-overseas/13813-cst-its-all-working-12.html#post181555

I swapped out the fuse for an LED glow-fuse from here :

LED 40A Amp MAXI Blade Fuse *Quantity 1* | eBay

When you remove the kettle plug don't damage the inner wire insulation or short the wires as you may end up with no BMS. Carefully remove the outer insulation then cut one wire at a time and cover the end with electrical tape.

Work on one wire at a time with the other covered or housed in a Powerpole. MOST IMPORTANTLY - don't go by wire colours to determine polarity and don;t believe any markings on kettle plugs as to +/-. The battery has AC wires & Chinese fitting on it and you need to use a multimeter then check and check again when you pair up the powerpole connector fittings.

 

[103Alex1]

Hi Alex,

Just ordering the bits you suggested and when I got to the inline fuse the one you linked it said max 32v. Is this the one you used and will it be ok for my 36v battery?

Thanks,

That's the exact same one I bought - same supplier. Works fine with 36V battery and I'm also running same controller plus all those extra things tapped off it.

 

[iain85]

Update, Anderson connectors are bloody hard to fit without the tool as indicated to me ( I didn't listen) tool now ordered.

I managed to short the battery terminals! Could I have damaged the Bms? I seem to still have 40 v which is good. /I'm an idiot

 

[Deleted member 4366]

I doubt that yoy've damaged anything. Deans are so much easier!

 

[103Alex1]

Update, Anderson connectors are bloody hard to fit without the tool as indicated to me ( I didn't listen) tool now ordered.

Takes a steady determined hand, considerable force and a multimeter probe or similar ... just don't slip and go through your hand ! I managed to fit them with 12AWG wire without the tool but did wreck a couple of pins practicing.

Deans are fine for power but for phase wires (where you have 3) it's handy to have an Anderson block in place of those bullet connector things.

I managed to short the battery terminals! Could I have damaged the Bms? I seem to still have 40 v which is good. /I'm an idiot

These sorts of things are easily done - especially when tired or in a hurry. Golden rule on battery wires - (apart from there being none) - always wrap the battery wire you aren't working on with insulation tape over the end or protect it somehow, even if you've cut the wires different lengths to work on. It only takes a second of distraction or a slip for them to touch. Sounds like your battery's OK though.

I've never slipped up with battery wires, but did manage to blow up a charger taking short cuts using a multimeter on some XLR pins seated in the surrounding metal housing instead of taking them out where there was no chance of the pins slipping onto the casing and shorting. Just so easy to do. A big spark and caput !

 

[iain85]

I'm using the Anderson connectors throughout. Some have gone well but some aren't quite pushed home so I have ordered the tool and will remake the dodgy connections. I consider myself fairly strong but could not for love nor money put any more force into pushing the connections home. I used some electrical screwdrivers initially but now im waiting patiently for the tool.

Good to hear I haven't damaged the battery, the spark was pretty impressive!