A full Bill of Materials is in progress! — 2017/06/21 23:16
The image below was found on the Golden Motor forum and was useful in deciphering the wiring. It probably still isn't the exact controller we have, but the wiring all matches up.
HALL EFFECT CONNECTOR
GND needs to pair with Orange, White, Purple, Red/Green, and Red.
(We are not using Cruise or Brake.)
We've broken out all the wires to a screw terminal block, numbered them, and added a label showing what is what. The connectors on the right side all have ring terminals crimped on them, and a bit of hot glue where the wire goes in as strain relief. The wires on the left (controller) side are all just put in by bare wire, but there is a lot of hot glue holding things in place.
The motor controller can be programmed using a special USB cable and Windows software from Golden Motors. The three areas we need to be most concerned with are highlighted in yellow. (We're mainly looking to deliver the most power we can without blowing the 30 amp fuse.)
Here's a helpful PDF that explains the programming parameters: Magic Pie3/Smart Pie Controller Programming
The diagram below shows how Pack #1 of the two packs get connected with copper bars and then how the wires from the balancing cables of the charger gets connected. (STILL TO DO: photos, Pack #2, and more instructions.)
Leaf Cells look like this when they come out of a Nissan Leaf. There's a lot of packs in there!
Each individual pack consists of two packs internally. You can check voltage on an individual pack by putting a multimeter on the center (white) connector and the the matching positive or negative connector depending on which pack you are testing.
You can stack up the packs to build larger packs. Make sure you've got the red terminal above the black terminal when you stack them.
Here's a stack of 3 cells, which comes out to about 28 volts. (Note: add color to this diagram!)
We made some copper bars to connect things up…
Here's how it looks with the copper bars in place so all the cells are connected into one larger pack. Note that there is a positive (+) and a negative (-) for your pack.
Caution! Do not short the pack in any way! Sparks will fly and bad things can happen!
Here's how the current flows through the pack when it's all put together. It's like magic!
We are using an iCharger 308 Duo 1300W 30A 8S Dual Port Lipo Life Battery Charger. The photo above was taken during testing so does not show all the balancing wires in place yet.
The charger is connected to a 24 volt power supply we had at the space. (Note: we need to add a better power cord to it, and cover the 120v terminals. Also, build a case for it all?)
The 308 Duo can charge and balance up to 16 cell (2 set of 8) so we can easily charge the 12 cells (2 sets of 6) we are using for the Wienermobile.
Here is a PDF manual for the charger.