Phev Insight

[gpsman1]

So how soon until you test drive the vehicle?
( watching with great anticipation! )

[retepsnikrep]

Another 5-6 weeks at least. I'm waiting for my new onboard charger to arrive, and still quite a bit or work to do on the car to prep it for the install.

1) Still tweaking/improving software.
2) Need to install display screen and buttons wires to front of car for BMS control.
3) Need to finish installing Master board etc into old oem battery pack shell.
4) Need to install 240v mains socket behind flip up rear number plate
5) Need to install and test new Zivan NG3 charger when it arrives.

So lots

[retepsnikrep]

Installed mains charge socket today. Rear number plate now flips up on little hinges and held shut with 2 magnets when down.

http://www.solarvan.co.uk/insight/chargesocket1.jpg
http://www.solarvan.co.uk/insight/chargesocket2.jpg

http://www.solarvan.co.uk/insight/chargesocket3.jpg
http://www.solarvan.co.uk/insight/chargesocket4.jpg

Working on BMS buttons and screen which will be fitted in the little cubby hole on right of steering wheel on UK car.

[IamIan]

Originally Posted by retepsnikrep

Installed mains charge socket today. Rear number plate now flips up on little hinges and held shut with 2 magnets when down.

Working on BMS buttons and screen which will be fitted in the little cubby hole on right of steering wheel on UK car.

Are you installing any warning or disable system so as to warn or prevent you from driving away with it still plugged in?

I've heard a few bad stories from some EV folks who forgot to unplug it one day and did some damage.

[JimIsbell]

Just make sure the pull is straight back and prop the license plate open. Then all you would get is a ticket for "obscured license plate".

Reminds me of the time I had a line come loose in the middle of the night (at at transient dock away from home) on my 44' ketch and the boat then turned out away from the dock and pulled the dock tower for AC hook up off the dock. I quickly removed MY dock power cable and then went to the other boat that was connected to it and (after retying my boat) woke them up to tell them that for some unknown reason their power line was in the water with the dock tower... Lest you think that was mean, they had been giving me a hard time all day long the previous day. The lesson to be learned here is, don't let your grandson tie the lines unless you check them afterward.

[retepsnikrep]

Originally Posted by IamIan

Are you installing any warning or disable system so as to warn or prevent you from driving away with it still plugged in?

I've heard a few bad stories from some EV folks who forgot to unplug it one day and did some damage.

I've heard those as well , I've had three EV's and never done it yet, but I have made sure it can pull out of the receptacle rather that pull the receptacle out of the car . Also I have a note which I shove infront of the guage cluster saying "ON CHARGE" I can't drive off without noticing that.

I may add a reed switch sometime, but how to disable the car using it is the question. I did include a "Drive inhibit" input and output on the BMS Master board so the software can play a part.

[retepsnikrep]

Just a few pics of the bms screen and buttons installation into the little cubby hole in my Insight. I'm not convinced it's in as good a spot as the litle screen would have been on the dashboard, but it is certainly discrete and less likely to encourage theft/breakin.

www.solarvan.co.uk/bms/CubbyHoleDisplay1.jpg
www.solarvan.co.uk/bms/CubbyHoleDisplay2.jpg
www.solarvan.co.uk/bms/CubbyHoleDisplay3.jpg
www.solarvan.co.uk/bms/CubbyHoleDisplay4.jpg
www.solarvan.co.uk/bms/CubbyHoleDisplay5.jpg
www.solarvan.co.uk/bms/CubbyHoleDisplay6.jpg


Need to do some testing on the buttons now but it seems to be working OK so far

[Mike Dabrowski 2000]

Nice work Peter
That's a great use of the little box.
Happy to see that your system is nearing completion.

[retepsnikrep]

Just a litle update, tweaked my display install and seperated video signal from within the multi core lead I used initially, it was functional but a bit noisy, now it looks crystal clear with separate ground and signal wires and a nice HQ coax cable and gold plated connectors Might as well get it right.

Two pics showing driving position and display/control, and another youtube video when it's finished uploading explaining it a bit more

www.solarvan.co.uk/insight/DisplayInstall1.jpg

www.solarvan.co.uk/insight/DisplayInstall2.jpg

Hopefully better audio quality this time on video as I changed encoder setting from Cheapskate 64kb to Imprudent 128kb

http://www.youtube.com/watch?v=SBYJXj4pUrk

Master current consumption testing on the BMS also quite comforting.

With screen on it's about 185ma from 12v supply

With screen off it's about 90ma from 12v supply

Once it's driving the charging relay that will rise a bit, but not bad and capable of running from the Car pb battery without much risk of flattening it unless left on for a week or so.

[highwater]

Originally Posted by IamIan

Are you installing any warning or disable system so as to warn or prevent you from driving away with it still plugged in?

I've heard a few bad stories from some EV folks who forgot to unplug it one day and did some damage.

I use a little 9v wall wart xformer (out of the junk drawer) on the on board charger rail; and used one of two, of the led indicators that had previously been used to indicate when the IMA/battery fans were both on, (MIMA runs them both, so now only one indicator needed) to give an indication that the grid power is connected. I still have to remember to unplug the cord after I shut off the grid power at the disconnect mounted on the garage wall, before I take off. Thats a matter of walking around the vehicle.

I had considerd adding a solenoid inside the shift console, perhaps with a forked tongue, to lock the shifter in nuetral, so long as the grid was connected. I think it could be done in a manner that would not create a safety concern while going down the road. Failsafe to the retracted position.


Randall