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12-29-2011, 05:57 AM | #1 |
Gone Mad
Join Date: Oct 2009
Location: Buford, GA
Posts: 8,988
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Volt Meter Idea
Here's how I'm currently wiring up my Alltrax Ex-Ray volt meter. I'm hooking up nine fused wires to a mil. spec. rotary switch, which has an adjustable stop to allow two (one would be silly) to twelve positions, two poles. I set mine for ten positions: off, batteries 1 - 8, and pack.
I currently have the warning and alarm set so that both LEDs flash when I do this (low voltage), but this is just an easy and free (discounting labor) way of monitoring each battery under load, while driving around. Nice to have hoarded clutter lying around! Crazy? |
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12-29-2011, 06:02 AM | #2 | |
Gone Mad
Join Date: Oct 2009
Location: Buford, GA
Posts: 8,988
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Re: Volt Meter Idea
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12-29-2011, 07:41 AM | #3 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: Volt Meter Idea
Old-School knob w/pointer.
And some demented musings from another Crazy. Move the stop out to twelve and use the two additional positions to monitor voltage drop across the Armature and the Stator, or across F/R contacts. Also, you're going to be connecting wires to every battery and to keep the smaller terminal lugs from interfering with the high current connections between the battery cables and the battery terminals, use stud extenders to connect the light weight stuff. |
12-29-2011, 08:35 AM | #4 | |
Gone Mad
Join Date: Oct 2009
Location: Buford, GA
Posts: 8,988
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Re: Volt Meter Idea
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12-29-2011, 09:23 AM | #5 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: Volt Meter Idea
Quote:
I lean towards overkill with high current connections. Each metal to metal interface is imperfect, so the fewer interfaces the better for maximum current transfer. I haven't done it yet, but the ring terminals from the charger receptacle are going to end up on stud extensions. The stacking order you listed is the way I would do it if stud extenders aren't used. FWIW: I had to replace a transformer in an X-Ray machine because the ring terminal for a monitoring circuit was stacked between the main cable and the transformer terminal, vaporized and the plasma cut nearly through the stud when a megawatt (200KV @ 5A) passed through it. Needless to say, the repairman that didn't read the manual got some remedial education from my size 16 boot. |
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12-29-2011, 10:23 AM | #6 | |
Gone Mad
Join Date: Oct 2009
Location: Buford, GA
Posts: 8,988
|
Re: Volt Meter Idea
Quote:
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12-29-2011, 10:41 AM | #7 | |
Gone Mad
Join Date: Oct 2009
Location: Buford, GA
Posts: 8,988
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Re: Volt Meter Idea
Quote:
You gotta love the din-rail fuse blocks. You'll notice I have 11 Weidmullers, while I only need nine for the battery voltage. This has got to be one of the most expensive fuse block installations in a buggy. I looked at various marine and automotive fuse blocks, but most have a common hot, while I need an independent in and out. |
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12-29-2011, 10:49 AM | #8 | |
Gone Mad
Join Date: Oct 2009
Location: Buford, GA
Posts: 8,988
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Re: Volt Meter Idea
Quote:
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12-29-2011, 12:05 PM | #9 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: Volt Meter Idea
I hear you on the lead w/SS stud & nut being far from ideal, but it's what we've got to live with until something better becomes readily available.
I'm going to be replacing my batteries in the not too distant future and I'm considering getting ones with EUT or UT terminals (Lead post with a hole through it) and use SS nuts and bolts. That way I can put the heavier lugs between the nut and the post and the lighter stuff, if any, on the other side between the bolt head and the post. Or maybe the other way around. Than I can use two wrenches and put a bit more torque on the connection as long as I don't put any angular torque on the lead post, which will still be fragile. Right now I working on a way to mount an Ammeter shunt (75 mV @ 500A) so it doesn't wiggle or put weight on the battery terminal while not blocking air flow through it. I had it all figured out and was getting ready to do some cutting, than I discovered the plastic I was making the bracket out of, was conductive. Now I've got to search through my stash of "might be useful someday" stuff some more. |
12-29-2011, 12:13 PM | #10 | |
Gone Mad
Join Date: Oct 2009
Location: Buford, GA
Posts: 8,988
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Re: Volt Meter Idea
Quote:
Cutting boards from WALMART are usually quite good, even at HV HF. |
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