I would recommend a twisted wire pair from the Battery+ and Controller+
connections back to the input of the hairball to reduce the possibility of
noise induced on the wires. Also follow the guidelines in the Zilla
manual,"The Zilla controller requires special attention to electrical noise
issues. This is because the unusuallyhigh currents of which they are capable
switching at very fast rates cause electrical noise.Signal wires should not be
run near the high power cables due to the likelihood of interference.
Aseparation of at least one foot between power and signal wires is customary.
Alternatively, the powerwires can be run in shielded enclosures or wraps.Power
wires are those which run between batteries, from the battery to the
controller, and from thecontroller to the motor.Signal wires include all other
wiring, but especially sensitive are the pot wiring, motor speed sensorwiring
and serial communication wires.In order to further reduce noise emissions,
power wires of a given circuit should be run together in closeproximity. For
example: The wires to the motor from the controller should all be close to each
other andsecured together with wire ties. The same goes for the battery
connections. Anytime power wirescarrying the same current in opposite
directions are not in close proximity, they form a loop. A loop isvery much
like an antenna and it transmits unwanted electrical noise.Signal wires should
also be run in sets. It is best to keep all the wires for a given circuit in a
tight bundle.The wiring to and from a device, such as a contactor or sensor,
should always be tight. "Also,"The Hairball has internal contactor drivers
which require snubber diodes on the contactor coils in order toabsorb the
inductive kick produced by the contactor coil when it turns off. Please note
these may not beshown in the wiring diagrams.The diodes which come with the
Hairball package have no polarity, they can be connected in eitherdirection
across the coil connection on the contactors. These diodes have a 24V threshold
so they arecompatible with the fast turn off required for Kilovac contactors as
well. "
On Sunday, September 6, 2020, 11:06:57 PM EDT, Matt via EV
<[email protected]> wrote:
Hi All,
I thought I would post a bit of an update
I tried a brand new hairball that I borrowed from a friend – the new hairball
also reported errors 1141 and 1124 when I tried to accelerate in any gear.
I had fused both contactor sense connections to the hairball, resulting in
longer wires running between the contactor terminals and the hairball
Connecting the hairball directly to the contactor with as short a wire as
possible resolved the issue, which suggests it may have been a matter of
induced noise in the measurement, of too short a duration for my DMM to have
picked up.
The noise issue likely hasn’t been sorted out, just that it is no low enough
that the hairball doesn’t fault
Matt
Sent from Mail for Windows 10
From: Jukka Järvinen
Sent: Thursday, 3 September 2020 7:04 PM
To: Electric Vehicle Discussion List
Cc: Matt
Subject: Re: [EVDL] Zilla 1141 error - 15mV drop across contactor at 100A
High power demand under acceleration could indicate current leaking to the
motor hull and messing up the car chassis ground (?) Brush dust issues have
kept me troubled too many times with weird problems.
-Jukka
to 3. syysk. 2020 klo 13.01 Matt via EV ([email protected]) kirjoitti:
Hi Brains Trust,
I have a Z1k LV.
My hairball gives me errors 1141 and 1124 when I try to accelerate in any gear
(worst in 5th, and least bad in 1st)
The manual tells me 1141 is contactor high resistance. my DMM measuring the
voltage across the battery and controller inputs to the hairball puts the
voltage drop at 15mV for 100A (battery amps that is). Which looks about right
for a good contactor
The contactor always drops out when I turn the ignition off, and my DMM
measures 92v across the contactor (measured at the hairball terminals). My
conversion is 96v nominal (actual battery voltage is 102v, though the little
white light on the hairball must act as a voltage divider, dropping 10v)
I opened the hairball, and it looks clean inside - nothing looks damaged
visually.
Any ideas on what to check next?
Is it possible to see what the hairball is measuring as the voltage drop across
the contactor?
thanks in advance,
Matt
Sent from Mail for Windows 10
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