We have added a laptop to the interior to facilitate downloading and graphing of data from the e-meter. This data displays both charge programing and discharge patterns. The laptop has its own caddy and mounting system, and operates off its internal battery as well as the vehicles 12v auxiliary power outlet.
Another view of the laptop set-up. At a later time we intend to integrate the individual battery monitoring system with the PC and track additional battery data.
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 wake-up back to life. Nife units perform better the more they are used.
We wanted to see the individual voltages on the 30 modules to asses condition so this is what we ended up installing. The meters mirror a typical battery box configuration. Three (3) batteries in the front row and 3 in the back row. The wiring is set-up to feed the meters displaying the left meter as the left battery, center meter as the center battery, etc. All we need to do is plug the RJ-45 link into the appropriate row selection RJ-45 plug 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 as shown by the black AAA boxes. DS and PS stand for Drivers Side & Passanger Side. The physical layout coordination is very helpful not only for servicing, but for understanding the effects of a single troubled battery on the adjacent units. ... and the box is nicely placed and out of the way.
Note the importance of each batterys front row connector vs. rear row connector. Without this set-up one row would read in reverse physical position 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 tow (2) RJ-45 boxes for each battery box, one front and another rear. We acknowledge that RJ-45s are not the best choice due to their lack of waterproofing; but we have been unable to find a properly waterproof RJ-45 style alternative. We consider that choice the weakest point of this system.
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 we would adjust that to a much lighter gauge in the next version.