Gen 2 EV Hardware
The Gen 2 EV hardware is now in the production stage. Most of the changes are to the Charger / DC-DC section which
is being revised to eliminate the Charge Detector module and simplify vehicle integration. The charger is now able to
handle the 120-240V AC input range as well. External cooling is provided by a DC rated fan vs the AC fan since the
fans can't handle a universal AC input. Because of the architecture changes in Gen 2, the internal relay that selected
AC/DC operation is omitted. Power output will be the same as Gen 1 hardware, limited by the isolation section. The
pricing should end up close to the same as the Gen 1 system, with some cost savings from the elimination of the Charge
Detection Module.
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Some new EV hardware coming down the pipeline: Updated 7/7/09

The Power Center (DC motor controller) will receive a 800A rating and be in a 10"L x 10"W x 5"T heatsinked
enclosure. Depending on pricing and order volume, it may become a liquid cooled configuration. It will have additional
output ports to monitor internal temperature limit and Current Control Mode (CCM), along with the standard inputs
currently employed. The temperature limit can feed a dash bulb (<150mA) or LED. The CCM mode can be monitored
as a dash lamp or LED indicator. When current falls below the commanded setpoint (full throttle condition), the lamp will
go out. You could invert this simply by inverting the signal before the lamp or LED. It could also function as a shift light to
maximize battery HP.

To make more use of the charging system, a 2.4kW model will be offered in 2 configurations.
The charging hardware has been upgraded into a 10"L x 10"W x 5"T heatsinked enclosure. It will have the standard
120-240VAC input range, with up to 1.2kW on the 120V line and 2.4kW charging on the 240V side (standard). A dual
AC input PFC option will allow charging from -2- 120VAC lines to charge at work with a 2.4kW rating (same power
on the 240VAC side) while retaining complete isolation from the AC line. A Dual Battery pack configuration is also an
option, whereby 2 (1.2kW) charging outputs are used to charge a front and rear pack, and to allow temperature
compensated charging to take place (Lead Acid). In this configuration, 2 contactors will be required. When the
contactors close, both packs will be placed in parallel. It would be possible to have a high performance lead / lithium
configuration option as well, but seeing how fast LiFePO4 is progressing may soon make this a moot point. The cost
increase for the new hardware is likely to be around $800-$900 (minus options) added to the current EV system price.
The timing for this is pushed out to mid 09 due to builds in the queue and rebuilding the dyno to handle more power. To
see where things are at in the pipeline, click on the
blog link. Here's the page dedicated to the 800A system. See also
individual front page links for the new hardware.
Thanks for your patience, building and testing new hardware takes time.
Updated
7/7/09