Monday, March 16, 2009

Control Board Layout

This past week I picked up several types of electrical crimp connectors, wire, and flexible conduit so I can get started with the main wiring. Yesterday, Richard drove down from Ottawa to bring me a few remaining parts and to spend the afternoon helping me with the switched 12 volt tap on the main fuse box and component wiring. When the battery was disconnected and we probed/tested our selected circuit relays for continuity, all appeared good. However, when the battery was connected, we did not get the 12 volts everywhere we expected. We originally identified two circuits (Cooling Fan and Additional Fan - 30 Amps each) but it seemed that the car's computer or something else was cutting out the 12 volts on one of the circuits. Although I had the service manual for the car, there were few wiring diagrams which were not detailed enough to answer our questions. After spending more than an hour and a half troubleshooting, we settled for one 30 amp switched circuit to power the vacuum pump and the other low current 12V equipment.

Next came the control board positioning and layout. Since there are no longer any plans to have pack batteries in the front compartment, there is plenty of space for the controller, pot box, main fuse, shunt, contactors, heater relays and fuses, vacuum switch control, DC-DC converter, 12v relays, and 12v fuse block (for vacuum pump and gauges). I cut out a template out of bristol board and Richard recommended a good layout. I then used that template to cut a piece of plywood that will be tested for proper mounting then trimmed again and cut for suitable openings (controller, wire feeds, etc). This board will be painted and mounted at a slight angle forward to allow any water to drain off should it get wet.

Below is a hand marked trace diagram of the control board wiring.

Here is the neater version of the above done using Visio on the computer.


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