Tuesday, May 30, 2017

Productive weekend

SIDE NOTE: We installed a 10000+ Lumen 100 watt LED light in the family room.  It has 4 CREE LED in it.  It is wired to two wall switches so we can run, 1,2, or 4 LED.  I learned that GFCI circuits do not like to share a common neutral as the circuit does not maintain current flow equilibrium.  A honey do project complete!


Like all things in this house, not available in stores, highly Lopified, very functional, beauty in in the eye of the beholder.  A twin to this light is in the garage as it was replaced due to a mfg. flickering issue.  I noted the drivers update 20 some versions between the units.  

Made the charger port connection.















Hopefully installed the Z-bars for the last time.  Sprayed some WD-40  into it to prevent rust.  Beveled and capped the ends.

You can see that the gearshift has been reinstalled and the vacuum pump has been mounted under the center of the I-beam.  Joshua has given us a vacuum reservoir from a VW Scirocco that will likely go in the drivers side wheel well.  And the control plan for the vacuum pump is to find a CAN based MAP sensor that will be used to control the pump relay and to throw a dash light if the vacuum fails.

Made a plate to cover the starter port on the transmission.
Removed an ear from the transmission as well next to the starter port for clearance to the I-beam.
You can see the vacuum pump clamped to the I-beam, it has rubber pads above and below the I-beam to isolate it from the frame.

Stuffed the first battery box.
11 Modules laid out for test and installation
It has been 1.5 years since these were charged.
They seem to be holding very evenly.
Perfect fit!
The heater and thermocouple wires are visible.
Just a wee overweight.  Original estimate was 100lbs,
A heavier gage metal was used to make the box,
and the cells with the brackets weigh more too...
The studs will be connected with rails to prevent movement near the bus bars.  The bottom of each studded module is bolted to the bottom of the box.  There are also 4 rods through the modules to transfer load from the non-studded modules to the studded modules.

Task list. This will be updated regularly.

Front Relay box

  • Will be mounted
  • Need to:


  • Create circuit diagram 
  • Create the BMS circuit connections diagram
  • Bus bars need to be reconfigured to fit. 

  • Plexiglas need to be cut to make box.

  • Rear Battery boxes

  • Will be mounted to the frame
  • Need to:


  • Create circuit diagram 
  • Create the BMS circuit connections diagram
  • Bus bars need to be reconfigured to fit. 

  • Lower battery frame needs to be cut to fit the box width.

  • Front Battery boxes

  • Will be mounted to the Z-bar
  • Need to:


  • Create circuit diagram 
  • Create the BMS circuit connections diagram
  • Bus bars have been reconfigured to fit. 

  • Top rails need to be cut and bolted down.

  • Water cooling pump


  • Will be mounted to the bottom of the I-beam
  • Need to:



  • Create circuit diagram 
  • Create hydraulic diagram
  • Create control program


  • Need to order:


  • Square U-bolts
  • Mounting plate 
  • Mounting bolts 
  • ΓΈ25mm id hose to/from pump 
  • Regulator switch 
  • Relay (check supply)
  • Reservoir tank (have) 

  • Vacuum Pump
  • Will be mounted to the front of the I-beam
  • Need to:


  • Create circuit diagram
  • Create Pneumatic diagram 
  • Create control program


  • Need to order:


  • Square U-bolts
  • Mounting plate 
  • Mounting bolts 
  • 3/8 hose from pump, what to booster check valve?
  • Regulator switch, Looking for MAP sensor with CAN output
  • Relay (check supply)
  • Reservoir tank (check supply) 
  • Check valve (check car)

  • Steering pump
  • Will be mounted at a much later date after the car is operational.
  • Will be mounted to the top of the I-beam on the passenger side between the windshield wiper fluid reservoir and the DMOC.
  • CAN codes have been found and are on a page specific to the pump.
  • Will require new hoses and fitting to be made.
  • Reservoir is built in and part of the return loop. 
  • Need to:


  • Create circuit diagram 
  • Create hydraulic diagram
  • Create control program

  • A/C compressor


  • Will be mounted at a much later date after the car is operational.
  • Will be mounted under the I-Beam on the drivers side.
  • Will require new hoses and fitting to be made.
  • Will require finding the CAN codes
  • Need to:


  • Create circuit diagram 
  • Create hydraulic diagram
  • Create control program
  • Thursday, May 4, 2017

    Finding data on the pumps that need to be mounted to the I-beam [Steering Pump]




    Part number :BG91-3K514-AB
    From the DIYer site we have found some communications data:

    Raising the control line high seems to power up the unit and it takes about 200mA. Pump does not rotate at all ...... would seem to need the CAN bus to enable and command speed. The unit announces itself on the CAN bus at power up as id 04f

    BO_ 128 x80: 8 pas
    SG_ SteeringWheelAngle_pas: 7|16@0- (0.1,0) [-1000|1000] "degrees" Vector__XXX
    SG_ SteeringWheelRotSpeed_pas: 23|16@0- (0.1,0) [-3000|3000] "deg/sec" Vector__XXX
    SG_ VehicleSpeed_pas: 38|15@0- (0.1,0) [0|327.67] "km/k" Vector__XXX
    SG_ SensorInitialized: 53|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ PumpEnable: 51|2@0- (1,0) [0|3] "enum" Vector__XXX
    SG_ SWARstatus: 49|2@0- (1,0) [0|3] "enum" Vector__XXX
    SG_ SteeringMessageNumber: 63|8@0+ (1,0) [0|255] "enum" Vector__XXX

    BO_ 662 x296: 8 pas
    SG_ VehicleSpeedCounter: 4|4@0+ (1,0) [0|15] "cnt" Vector__XXX
    SG_ VehicleSpeed: 23|16@0+ (0.01,0) [0|320] "km/h" Vector__XXX
    SG_ VehicleSpeedQF: 39|2@0+ (1,0) [0|3] "enum" Vector__XXX
    SG_ VehicleSpeedUB: 35|1@0+ (1,0) [0|2] "Boolean" Vector__XXX

    BO_ 644 x284: 8 pas
    SG_ PowerModeUB: 5|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ PowerModeQF: 9|2@0+ (1,0) [0|3] "enum" Vector__XXX
    SG_ PowerMode: 38|5@0+ (1,0) [0|10] "enum" Vector__XXX
    SG_ CarMode: 45|4@0+ (1,0) [0|15] "enum" Vector__XXX

    BO_ 1195 x4AB: 8 pas
    SG_ PowerModeExt_D_actlUB: 32|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ PowerModeExt_D_act: 47|5@0+ (1,0) [0|11] "enum" Vector__XXX

    BO_ 1024 x400: 8 pas
    SG_ VehConfParamHS8: 7|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehConfParamHS7: 15|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehConfParamHS6: 23|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehConfParamHS5: 31|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehConfParamHS4: 39|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehConfParamHS3: 47|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehConfParamHS2: 55|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehConfParamHS1: 63|8@0+ (1,0) [0|255] "u8" Vector__XXX

    BO_ 1029 x405: 8 pas
    SG_ VehInfoParamHS8: 7|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehInfoParamHS7: 15|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehInfoParamHS6: 23|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehInfoParamHS5: 31|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehInfoParamHS4: 39|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehInfoParamHS3: 47|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehInfoParamHS2: 55|8@0+ (1,0) [0|255] "u8" Vector__XXX
    SG_ VehInfoParamHS1: 63|8@0+ (1,0) [0|255] "u8" Vector__XXX

    BO_ 320 x140: 8 pas
    SG_ EngineSpeedQF: 54|2@0+ (1,0) [0|3] "enum" Vector__XXX
    SG_ EngineSpeed: 52|13@0+ (1,0) [0|8191] "rpm" Vector__XXX

    BO_ 118 x76: 8 pas
    SG_ SteeringAngleSign: 6|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ SteeringAngleStatus: 5|2@0+ (1,0) [0|3] "enum" Vector__XXX
    SG_ SteeringAngleCounter: 3|4@0+ (1,0) [0|15] "cnt" Vector__XXX
    SG_ SteeringAngleCS: 15|8@0+ (1,0) [0|255] "enum" Vector__XXX
    SG_ SteeringAngleCRSign: 23|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ SteeringAngleCRShortFilt: 22|15@0+ (0.06104,0) [0|2000.09768] "deg/s" Vector__XXX
    SG_ SteeringAngleCR: 38|15@0+ (0.06104,0) [0|2000.09768] "deg/s" Vector__XXX
    SG_ SteeringAngle: 54|15@0+ (0.04395,0) [0|1440.10965] "deg" Vector__XXX

    BO_ 576 x240: 8 pas
    SG_ EpasFailed: 15|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ Ehpas_IDC_mode: 9|2@0+ (1,0) [0|2] "enum" Vector__XXX

    BO_ 79 x4F: 8 pas
    SG_ EngRun_D_ReqSte_UB: 63|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ EngRun_D_ReqSte: 62|2@0+ (1,0) [0|3] "enum" Vector__XXX
    SG_ EPSWarningEHPAS_UB: 57|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ EPSWarningEHPAS: 56|1@0+ (1,0) [0|1] "Boolean" Vector__XXX

    Reference:

    BO_ 128 x80: 8 pas
    ID in decimal xin hex: number of bytes in packet Subsystem (Power Assist Steering, pas)
    SG_ SteeringWheelAngle_pas: 7|16@0- (0.1,0) [-1000|1000] "degrees" Vector__XXX
    signal name: startbit l number of bits @sign (resolution, offset) [min value l max value] "units"

    SG_ SteeringWheelRotSpeed_pas: 23|16@0- (0.1,0) [-3000|3000] "deg/sec" Vector__XXX
    SG_ VehicleSpeed_pas: 38|15@0- (0.1,0) [0|327.67] "km/k" Vector__XXX
    SG_ SensorInitialized: 53|1@0+ (1,0) [0|1] "Boolean" Vector__XXX
    SG_ PumpEnable: 51|2@0- (1,0) [0|3] "enum" Vector__XXX
    SG_ SWARstatus: 49|2@0- (1,0) [0|3] "enum" Vector__XXX
    SG_ SteeringMessageNumber: 63|8@0+ (1,0) [0|255] "enum" Vector__XXX

    UPDATE:
    This pump will be mounted between the windshield washer fluid reservoir, and the DMOC.  The required orientation and height prevent it from being mounted under the I-beam as originally intended.  A plate will be made that will mount to the top of the I-beam and the side of the pump.

    Finding data on the pumps that need to be mounted to the I-beam [Vacuum Pump]


    Vacuum pump


    This pump was for the Ford Transit Connect electric vehicles. Ford part # A426C.

    Voltage: 12V
    Full Load Current: 12 Amps
    Continuous Current: 8 Amps
    Vacuum: 25+ in of hg
    Vacuum Port Size: 3/8 Inch Hose Barb
    Weight: 2.7 kg

    Data I am still looking for:

    Which way is up? Does this pump have a preference as to which way it is mounted in the car? Does anyone have installation instructions, or maintenance requirements? It is oiled?

    UPDATE:
    I will mount it with the motor up and the breather down.  Thus as it sucks wet air through it any condensate will hopefully migrate out rather than into the motor.

    This pump will be placed in front of the I-beam near the center.  It will be hard mounted to a plate, the plate will sit on a rubber pad on the I-beam for vibration isolation.  The plate will be held in place by a pair of square u-bolts sandwiching the I-beam.