1961 Volvo PV544 - Now EV544

[jclars]

Yeah, no worries yet. Maybe you are onto my next project, which has only been alluded to so far. A Lexus hybrid into a 1950 Plymouth. I foresee lots of heavy physical work. So I have started a call list of young able bodied friends (male and female) who I can call on for sporadic assistance!

I don't go down easy, but sometimes foolishly. I have called the last three cars I have worked on my "last one". Well, this WILL PROBABLY BE my real "last one"! Then it will be maintenance of the herd!

And I probably won't be painting it either!

[jclars]

Now back to the regular program, following a somewhat low production Christmas holiday due to sickness, and family chaos.

The front contactor initiates the connection of both 60 volt packs to the controller/inverter. Although there is a maintenance shut off switch to manually separate the two packs as well. So that makes a total of 4 shut off switches: A 12 volt battery shut-off, contactors at front and rear which open when 12v key switch is off, and the manual maintenance switch.

In the front contactor box you'll find another main HV fuse, and HV connections going to the rear charging system, including 30 amp fuses. I also included a shunt, which I did not use, instead going to a hall effect sensor for current measurement.

The inverter/controller was conveniently located in the original 12v ICE battery shelf (center of firewall). It has a water cooled heat sink behind it, which was actually required on the single hot summer day (90*F+) I happened to drive it. I therefore added a temperature gauge on the base and put the pump on a manual switch, as it may never be activated anyway. You can see the blue water line in the pick which goes to a small ATV radiator up front.

[jclars]

All HV conductors - 2/0 AWG for battery, 8 AWG for charging - are routed below deck and protected by the enclosed drive line tunnel. Outside the tunnel they are protected inside flexible metal conduit.

The rear contactor connects main positive from rear battery pack with 300A fuse to front battery box main negative, completing the series connections.

Main rear negative is the full voltage (120) battery terminal, going to the front contactor box and from there to the controller B- terminal. Main front positive is the full voltage (120) battery terminal going into the front contactor box, through another 300A fuse, and then switched by the contactor upon key-on. This completes the link to the positive side of the controller B+ terminal.

Charging circuit draws power at the front contactor input and is routed through 30A fuses before diving below deck.

Clear as static.