Battery Charger

Manzantiz Micro PFC-20 EV battery charger.

I paid an extra $400 for the optional front panel AC ammeter. I use the meter several times a day (every time I charge) and despite being so pricey, I would regret not having it.

At home can charge at 12 miles per hour (using 230v), meaning for every 12 miles I drive, I need to charge for 1 hour. At work I can only charge at 5.5 miles per hour because I'm using 115v.

Here is a list of Bay Area charging stations.

I added two blower fans inside the trunk, they suck the hot air from the charger, and exhaust it out the rear of the trunk lid.

I also added a small 12-15 volt power supply which is powered by the 120/240 AC charging receptacle.

This supply powers the thermostatically controlled blower fans, and an interlock relay which disables my inverter while the car is being charged. The interlock relay ensures I don't drive off with the charging cord plugged in. It is nice to have a spare DC-DC converter, although this DC-DC is only 90 watts, it should be enough to keep the car running should the 750 watt DC-DC fail. I wired both DC-DC converters with identical power plugs so they can be easily switched.

Charging port

All I have to do is plug in the cord, and the car will start charging.

I wired in a GFI and timer to take advantage of our $0.03/kWhr electricity rate after midnight. Electricity during peak hours is 9x more expensive! Charging from midnight to 7am brings my cost per mile down to 0.5 cents per mile ( I charge at work for free 50% of the time).

Gas Gauge

This is my LinkPro "gas gauge". It counts the Amp hours consumed while I drive, then counts the Amp hours when I charge. The gauge is amazingly accurate, and gives me peace of mind knowing exactly how much charge is left in the pack. It reads 0-500A and can resolve down to 0.1A, much more accurate than my analog gauge.

This is the shunt included with the LinkPro meter, this is how it measures current.

The shunt is nicely tucked away behind the wire duct cover

The LinkPro is powered with 12 volts, but the shunt is connected to the 330 volt pack. I used an isolated power supply to power the gauge so my 300 volt pack is completely seperate from my 12 volt system.

Charging stations

Charging stations at Solyndra

J1772 EV Charging plug

I bought the SAE J1772 plug for $125, now I can charge 3 times faster using Level II public charging stations.
Level I is 16A @ 115V
Level II is 32A @ 208/230V

Note: This is the pin side view, the wires come out the other side. The switch shown is used to enable the charging station once your charger is ready to start charging. One could leave this switch closed and have the connector supply power immediately once it is fully plugged in. Don't forget to connect the ground to the chassis of the car!