I did end up swapping the 4P4C wiring between the Chargery screen & brain. It works fine now.
Finally, I did throw the big switch. The spark & pop produced when the circuit was completed was not trivial. It actually very slightly blackened the contact. You may notice dielectric grease in the picture as I used on all critical connections. It would make me think twice about opening or closing the switch unless in an emergency. Is this normal? Is there a way to avoid or reduce the effect?
It was surprising and concerning but did no damage as far as I can tell.
- I flipped the main GEM breaker and everything came back to life!
- Successfully completed the first charge.
One note… when the charge is complete at just under 82v or 94%, I noticed that the GEM dash screen would periodically come on and show 99% and charging for about 30 seconds. This was concurrent with the green enable LED from the BMS. It seems that it is just topping off the charge. At this point any cells that were slightly above 4.1v (like 4.105) showed as “High”. Is this normal to cycle the charger on an off after reaching full charge? Do you guys put the charger on a timer or just leave it plugged in?
Anyway, at this point all the main systems in the box are installed. Battery, BMS, Inverter, Solar controller, 5v supply for LED lighting.
Next on my list:
- Dash work: 3 switches for lighting zones, inverter switch, solar switch. Also want to make some kind of mount or box for BMS screen & solar control.
- 120 VAC wiring (outlets in cab, Bed / Max Box, external on rear end) you can see the gray UF cable dangling & taped.
- Install solar panel on roof rack. You can see the white marine grade 12ga DC cable dangling & taped. The solar control is powered by the panel so I did not get to power it up yet.
- LED addressable pixel strips and controller
- Add 4-pin trailer light wiring.
I will probably test drive it in the near future so I have a baseline. Then I will install the magic magnet and test. Finally I will swap the motor for the Ride-4-Fun motor.
Here are some current pictures