1993 Chrysler TEVan - BEV
We needed to
see the individual
voltages on the
30 batteries to
asses condition
so this is what I
thought up.

The meters mirror
a typical battery
box.  3 batteries
in the front row
and 3 in the back
row.  The wiring is
set-up to feed the
meters so the left
meter is the left
battery, center
meter the center
battery, etc.

All I have to do is
plug the RJ-45 link
into the appropriate
row selection RJ-45
and it reads that
rows voltages in
proper physical
order.
Here is a
close-up of the
meter system.  
Each meter
requires its own
power supply, the
black AAA boxes
as pictured.

DS and PS stand
for Drivers side &
Passanger side.

The physical layout
coordination is very
important now only for
servicing, but for
understanding the
effects of one troubled
battery on the adjacent
units.
... and the box is
nicely placed and
out of the way
Note the
importance of
each battery's
front row
connector vs. rear
row connector.  
Without this set-up
one row would
read in reverse
physical postion to
actual.
This is the battery
box interior wiring
plan.  Although
shown as crossing
the battery, no
wires cross any
other wires in this
system.

There are 2 RJ-45
boxes for each
battery box, one
front and another
rear.

I acknowledge that
RJ-45s were not the
best choice due to
their lack of
waterproofing; but I
have been unable to
find a waterproof
RJ-45 style
alternative.  I consider
that choice the
weakest point of this
system.  Suggestions
welcomed, as always.
Here is a view of
the interior battery
box wiring.  The
wires are kept all
to the outside of
the batteries and
no two wires cross
each other to
avoid any possible
shorting.

Interior box wiring
is standard
automotive 18
awg, although I
would adjust that
to a much lighter
gauge if I ever do
this again.
The RJ-45s from
another angle.
Another view of the
LapTop set-up.

At a later time I
intend to integrate
the individual
battery monitoring
system with the PC
and track
additional battery
data.
I have added a Dell
LapTop to the
interior to download
to graph data from
the e-meter.  This
data shows both
charge programing
and discharge
patterns. The
LapTop has its own
caddy and mounting
system, and
operates off its
battery as well as
the vehicle's 12v
auxiliary power
outlet.
A download
showing a pair of
40 amp heat
discharges
followed by a pair
of charging
cycles.  Note that
the second
charging cycle
pushed the
voltage cycle three
times rather than
two.  The battery
pack had been in
storage for many
months before this
event; and it
shows the
batteries starting
to come back to
life.  Nife units
perform better the
more they are
used.
A closeup of the
RJ-45s.
Individual Battery Monitoring Systems
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