I would be careful to stay within the design limits of the Czonka contactors. Partly because of good practice, partly because you can't inspect for damage, and partly because you really want them to work every time.
I also might suggest using Cam-Lok connectors instead of Anderson at those voltages. They are more difficult to deal with but have MUCH better sealing. Just an opinion about working on 300V packs. Especially ones that get wet/dirty/salty or all three at once. Seth Gary Graunke wrote: > > Having looked at the Insight battery module and my other EV, a US Electricar > S10, I noted that both have a switch in the middle of their battery packs. > Both are unreachable while driving, so it would be a fair assumption that > are not used as quick disconnects, but more for safety while servicing the > battery packs. > > So far I have design with two battery boxes in the works for the Insight. > One where the gas tank used to be, and a second where the Insight battery > pack and motor controller were. The gas tank one is fairly inaccessible, > requring one to jack up the rear end and lower the battery box, though a > NiCd watering system could easily reach it from above. The other is easily > reached in the back. > > I'd like to have a switch in the middle of each box, as well as a fuse in > each box. And I'm thinking about adding Anderson connectors to each box so > that it can be unplugged. Ideally, I would like a method of breaking the > pack voltage up into segments of 60 volts prior to opening the battery > boxes, either by a switch or Anderson connector. > I'm planning on using a 240V pack, but some alternatives would go as high as > 312V (depends on battery availability). > > My questions are: how much resistance will each of these items add (fuses, > switches, and connectors)? > > Does anyone know of suitable DC rated switches (say 300+ VDC and 300A)? > > Would the nice little $75 Kilovac Czonka-III contactors work in place of > switches (just drop the 12V and the switch is open, but draws a bit of juice > to hold it closed). > > Comments? > > Gary -- vze3v25q@verizondotnet
