Sorry to hijack the thread but I have a potentially serious concern.
I have 12 modules / 24s of 2012 AESC modules from a Leaf in my motorbike. Today just before making the last connection from positive to the contactor I accidentally touched the lead to the chassis, had a spark and some copper welded. The chassis is obviously not supposed to carry HV-, not even 12V-, typical on a motorbike.
At first I suspected the negative lead around the fuse and the Kelly controller, but they have no continuity to ground. A full short at 92V would have been much more disastrous and should have blown the fuse. With a multimeter I measured voltages of up to 1.6V to ground from various points of the pack. The voltage only registers briefly.
I disconnected all the leads and even the interconnect to isolate - no luck.
I removes the lower 4 modules and took the whole harness off.
Now I can measure from various points and have the same thing all over the place, nearly every 2nd connector register 0.1-0.3V briefly, even on the 4 modules that are now completely removed from the bike. Double-checked with a 2nd multimeter as I thought I'm going crazy.
I am suspecting that the exposure to the elements has breached some kind of seal and I have a "bit of a short" to the cans. The obvious questions:
- Can anyone else confirm this?
- Is this a big issue? HV leads anywhere have to be handled carefully anyway. Kelly & contactor will be driven by dedicated LV pack, but should I isolate the controller from ground? They are known to have some ground issues. I could isolate the individual modules on the lower pack, but the upper one is a bespoke, tight fit...
- Anything else i should test?
A picture: