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Old 04-11-2009, 07:35 AM   #876 (permalink)
Roger Heuckeroth
EV Converter
Join Date: Mar 2009
Location: Saugerties, NY
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I was laying in bed last night thinking about the failure, and I woke up at 3:30 AM with possibility that I don't think any of us were considering.

Ben do you have a freewheel diode across the main contactor? If you don't it is possible that the inductive kick back from the main contactor sent a voltage spike back to the controller board that KO'd the DC/DC converter. If this happened when you shut off the car, then when you got back and turned the key the control board was dead and so you suffered a similar fate to Paul's out of sequence failure on the bike controller.

Its easy enough to diagnose. Just check to see if the DC/DC converter is dead. If it is then I bet that's what happened. If not, we can at least eliminate that possible failure mode.

In any case its a good idea to put a freewheel diode across the contactor coil to prevent these spikes.
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