Motor over temp relay - EA manual errata?

[Mike Brown]

Well I tested the 12V circuits for the first time and found the motor
over temp light (formerly red alternator light) was constantly lit.
Tracing the circuit documented by EA looked correct. Then I checked
the specs on the Netgain Warp 9 and found the motor over temp snap
switch is closed when cold, so lighting the light is the correct thing
to happen.

I'm guessing that the Warp motor over temp switch used to work in the
opposite fashion, and the EA manual was written to that spec and then
not updated when the Warp changed. Either that or the EA manual is
just wrong.

I found a couple of other issues with the EA instructions:

1) The charger defined in the manual is wrong; it's written for an
LB-20 booster and a BC-20 charger but I have a single Zivan.
2) The DC-DC converter has a wiring harness rather than the terminal
blocks as defined in the EA manual.

I worked around these problems, but as I cleverly put all of the
relays, contactors and terminal blocks inside NEMA-rated weatherproof
enclosures, I don't have room left for the motor over temp relay
required to fix the light problem. I found the relay in a marked
ziplock bag at the bottom of my parts box, but of course the
instructions never called for it.

I've written up a little circuit and will upload a scan of it. Has
anyone else run into this problem? I vaguely remember reading about
it a long time ago on somebody's blog but Google can't find it now.

Mike Brown
No, not that one, another one

[Peter Thompson]

Could be worse - your manual could have been a printout of the DC
motor manual, with a word doc that you were supposed to print out and
then paste (or tape) into the manual producing the AC motor manual.
Of course, it was also wrong.

I spent about a year working with the manual to the letter only to
realize that it would never, ever work. That's when I threw it out
and started from scratch. This included rewiring ALL of the relays
and such.

My suggestion: find someone that is willing to give you a block or
wiring diagram for your controller and charger. I'd give you mine,
but it is for the AC24 motor and the PFC-20 charger. (Oh, and it no
longer exists on my system somehow, not sure how I lost it).

Best of luck,
Peter