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The most useful of all your EV on-board instruments is your ammeter The dual-scale model shown in Figure 9-15 (top left) delivers 0- to 50-amp or 0- to 500-amp monitoring ranges at the flip of a switch The higher range enables you to determine your motor s instantaneous current draw; it functions much like a vacuum gauge in an internal combustion engine vehicle the less current, the higher the range, and so on The lower range functions the same as the ammeter that might already be on the instrument cluster of your internal combustion conversion vehicle it tells you the amount of current your 12-volt accessories are consuming
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Ammeter cur rent shunts 50 amp (left) and 500 amp (right)
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Figure 9-15 Instrumentation meter s ammeter (top left), voltmeter (top right), batter y indicator (center), temperature (bottom left), and rotar y switch (bottom right)
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The second most useful EV on-board instrument has to be your voltmeter The dual expanded-scale model (Figure 9-15, top right) delivers 50- to 150-volt or 9- to 14-volt ranges at the flip of a switch Expanded scale means only the required voltmeter range is used; the entire scale is expanded to fill just the range of voltages you use The higher range enables you to determine your battery pack s instantaneous voltage (it functions like the fuel gauge in your internal combustion engine vehicle the less voltage, the less range remaining The lower range functions like the voltmeter that might already be on the instrument cluster of your internal combustion conversion vehicle it tells you the status of your 12-volt system
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Users seem either to like the battery indicator a lot or find it redundant (with the voltmeter) so investigate before you invest The Curtis Model 900 version (Figure 9-15 center) indicates battery pack state-of-charge as of your last full charge-up using a 10-
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element LED readout The battery indicator is wired directly across the battery as if it were a voltmeter Proprietary circuitry inside the module then integrates the voltage state into a readout of remaining energy that s displayed on one of the 10 LED bars While this is not as useful for those employing on-board charging, and certainly does not come close to being a battery energy management system, it is useful for those who charge only from a fixed site as a guide to when the next pit stop is required
Temperature Meter
While your lead-acid-battery-powered EV won t run at all if it s very, very cold, you can use it again when the temperature rises At the high-temperature end of the scale, you can cause permanent damage to your batteries, controller, or motor if their temperature limits are exceeded A temperature gauge certainly falls into the nice-to-have rather than the mandatory category, but if you are so inclined, an easy way to keep tabs on temperature is by using a thermistor and a temperature gauge like the one shown in Figure 9-15 (bottom left) Or you can use multiple thermistors one bonded to each object of interest (battery pack, controller, motor, etc) and monitor all by switching between them
Rotary Switch
Rotary switches such as the four-pole, two-position switch shown in Figure 9-15 (bottom right) are ideal companions to your instrumentation meters for range, sensor, and function switching While you can opt for only an ammeter and a voltmeter in your finished EV, you might want to check voltage and current at numerous points during the testing stage A handful of rotary switches helps you out in either case
Fans
Fans fall into the mandatory category for keeping temperature rise in check for engine compartment components, or for keeping the battery compartment ventilated during charging Whether DC-powered full time from the key switch circuit, DC-powered intermittently via relay closure, or powered from an AC outlet, the spark-free brushless 12-volt DC motor fans and 120-volt AC motor fans are the type you want to choose
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