Wire the Drive System

Once all the components were installed, I wired the drive system.  Busbars were used to connect most of the modules in series.

battery1

Three of the short cables used in the bench test were used where I needed diagonals to connect modules in series.  The only reason I needed to do this was that I received an uneven number of left/right terminal configured battery modules.

battery2

I connected all the high-current cables first, since they were stiff and required a little finesse.  I routed them in a way that would not create tight bends, leave too much slack, chafe on sharp metal edges, or interfere with the chain or rider.

Cables1

I was able to re-use the cables from the bench test, but in many cases I had to cut off one end to shorten the cable or to route it through a grommet before attaching.  Fortunately, I had extra lugs.

Cables2

I connected the smaller wires next, routing them around the frame in the most inconspicuous way and securing them with zip ties.  I referenced the schematic diagram many times to ensure I had it right.

wires2

 

cables3

When the drive system was wired up, I turned the key and hit the run switch.  Thankfully, the relay and contactor clicked, and the controller and Cycle Analyst came alive.  I twisted the throttle gently and the shaft turned!

At that point, the desire to ride became irresistible.  So instead of working on the 12V system, I installed the sprocket and chain.

Next:  Sprockets and Chain

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