Archive for the ‘testing’ Category

The importance of tight bolts with high voltage

Electronics, testing | Posted by admin November 14th, 2010

I learned an important lesson today. I had changed out a few of the Zener battery balancers and hadn’t tightened down the bolts on one of the terminals. When I took the car out for a test run I noticed a bright flash in my rear view mirror in the top of the battery pack. I immediately got off the peddle cutting the flow of electricity and pulled over. What I found was that one of the terminals I had just worked on was blackened and the nut and washer were noticeably damaged by what had been arcing electricity. Without the bolt being tightened the copper plate was loose enough on the terminal that a bump in the road had cause it to jump a bit. The high voltage electricity just jumped this tiny gap producing an arc. Needless to say I cleaned up the terminal, replaced the nut and washer, and the rechecked the connections on the rest of the pack.

168 volt tests

testing | Posted by admin October 31st, 2010

Controlled Driving Tests

These were all driven on normal roads in normal traffic. Stops occurred approximately every 2-3 miles.
Battery pack is comprised of 16 Odyssey 2150 AGM batteries for a pack voltage of 168 volts at 12 volts per battery.

Oct. 17

Battery voltages start

178.9 volt total pack

35psi tires
Odometer reading 362.28 start

Bank A Bank B Bank C
  1. 13.0
  2. 12.9
  3. 12.7
  4. 12.8
  5. 12.8
  6. 12.7
  1. 13.0
  2. 12.9
  3. 12.8
  4. 12.6
  1. 12.8
  2. 12.8
  3. 12.8
  4. 12.7

Final battery voltages

Bank A Bank B Bank C
  1. 11.9
  2. 12.2
  3. 11.4
  4. 11.5
  5. 11.1
  6. 11.2
  1. 10.3
  2. 8.7
  3. 11.1
  4. 11.1
  1. 11.6
  2. 11.1
  3. 11.5
  4. 12.0

Pack total 161 volts

Odometer reading 378.84 end
16.56 traveled by odometer*

17.8 traveled by GPS
37.4mph average
Top speed 53 mph
Stops every 2 miles

38ah spent according to Zillaview

Oct. 18

Starting voltages
Bank A

  1. 13.1
  2. 13.0
  3. 12.9
  4. 12.8
  5. 12.9
  6. 12.9

Bank B

  1. 12.7
  2. 13.0
  3. 13.1
  4. 12.8

Bank C

  1. 12.9
  2. 12.9
  3. 12.7
  4. 12.8

180.3 pack voltage
OD 378.84 start
OD 399.10 end
35psi tires
33.1mph avg speed
49.4 max
42ah used
21.6 miles via gps

Final pack voltage
Bank A

  • 12.1
  • 12.2
  • 11.7
  • 11.7
  • 11.5
  • 11.6

Bank B

  1. 11.1
  2. 10.0
  3. 11.6
  4. 11.5

Bank C

  1. 11.5
  2. 11.8
  3. 12.1
  4. 11.8

162.5 volt

Oct. 19

180.3 v pack
OD 399.1

Bank A

  1. 13.1
  2. 12.9
  3. 12.8
  4. 12.7
  5. 12.8
  6. 12.9

Bank B

  1. 13.1
  2. 13.0
  3. 13.0
  4. 12.7

Bank C

  1. 12.8
  2. 12.7
  3. 12.8
  4. 12.8

Final Voltages

Bank A

  1. 12.3
  2. 12.3
  3. 12.0
  4. 11.9
  5. 11.9
  6. 12.0

Bank B

  1. 11.6
  2. 11.7
  3. 12.0
  4. 11.8

Bank C

  1. 12.0
  2. 11.9
  3. 12.2
  4. 12.0

167.9 v pack
OD 413.44
15.2 miles on GPS

39.5 mph avg. 75mph max

Oct 31

OD 423.58

Pack V 183.1V

Bank A

  1. 13.3
  2. 13.2
  3. 13.0
  4. 12.9
  5. 13.1
  6. 13.1

Bank B

  1. 13.0
  2. 13.1
  3. 13.0
  4. 13.0

Bank C

  1. 13.0
  2. 13.1
  3. 13.0
  4. 13.0

Ending voltages

Bank A

  1. 12.0
  2. 12.1
  3. 11.7
  4. 11.7
  5. 11.5
  6. 11.6

Bank B

  1. 10.5
  2. 9.6
  3. 11.7
  4. 11.4

Bank C

  1. 10.9
  2. 11.7
  3. 12.0
  4. 11.8

23.4 miles taveled via GPS

35.6mph avg. 57.6 max

Odometer 445.16ery