On 6/13/2024 2:42 AM, Bill Dube via EV wrote:
Sound like something is not quite right. These contactors should last
forever, basically.
Back to looking into this. (yeah, busy week - and I had to drive the
gasser. UGGHH!)
My last trip, one of the contactors cut out twice while driving.
Then, when I got home, I found that the truck had developed a
significant ground fault. (previously, it had been about 3ma - enough to
sometimes trigger the J1772 shut off at some stations.) At home, I just
plug into a 14-50. (PFC-50 charger)
After the trip, I plugged it in - and heard crackling! Unplugged it,
and started swearing.
Now, for some history.
I recently had to replace the 12v battery, as I found that it was no
longer taking a charge.
Note that I hadn't noticed for a while since as I turn on the key, the
DC-DC comes on. It does require the Neg contactor to be turned on, but
apparently that was successful.
I had noticed that the DC-DC was putting out more current than usual,
and was trying to figure out what I had left on to run the battery down.
I couldn't find a significant draw on it when the truck was off.
I did have one occurrence of the Zilla cutting off, (99% sure due to the
contactor) during this time.
Then one day, it wouldn't come on at all, and the 12v was obviously low.
(dim dome light)
I replaced the battery, and all seemed to be fine.
Then on this last trip, it cut out twice, both times when accelerating
up hill.
Got the Zilla status codes.
Main Contactor High Resistance
12v under voltage
I'd bet the 12v under voltage is from just before replacing the battery.
I just did some poking around with the meter.
Pos contactor is stuck ON. (might be high resistance, but enough on so
that the meter reads full pack voltage.
Also note that due to this, the Zilla won't turn on - so I can't move
the truck down to the shop. PITA.
It is interesting that the Zilla re-engaged on the trip - but won't now.
Need to figure out how the sudden bad Ground Fault is connected to the
whole mess.
I'm going to be carting tools back and forth about 150' in the rain.
(The truck is in a dry car port! Not gonna have to work in the rain.)
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