Bruce {EVangel} Parmenter 1985 S-10 Blazer Electric Vehicle conversion

I have recenlty replaced my old pack of 22 US145"s for 22 US125's. My current job pays the bills, allowing me to work on completing a Degree. But it does not allow me the money and time freedom I once had when working for Hewlett-Packard as a Customer Engineer. Since I can not go everywhere and do everything that I used to be able to do, I drive less far than before.

So I figured I would replace my pack with a less capacity traction wet-cell, save some money, and try these out. My range when down from an easy 50 miles to 42 miles. My wieght savings is only about the weight one battery (not much). The cost saving was large, about 30%.

This is because many more US125's are sold by my distributor than US145's. I was paying a preimum for the large capacity US145's because he did not sell as many of them.

I also have a new PFC charger. I had sent my PFC-50 in to the factory for upgrades. The shipping carrier had lost my shippment. I was smart enought to insure the shipment, but I should have insured it for the full replacement cost (I lost about $300).

This time instead of buying another PFC-50 which is a great charger, I decided to buy a new model, the PFC-30. It cost less and it fits my needs better. I mostly have access to a 208-220 VAC 40 amp source (either 14-50 or via an AVCON). I could not use all the charging capability of the PFC-50. The PFC-30 is a perfect fit for those charging off an AVCON source.

I use my PFC-30 connected via an AVCON adaptor. The AVCON charging head plugs into the adaptor, and the charger draws its power from a 14-50 on the side of the AVCON adaptor box. These AVCON adaptor boxes are available from the EAA http://eaaev.org

Off an AVCON or 40 amp 208-220 VAC source, I turn the PFC-30 all the way up to maximum output. I get 36 amps at 150 VDC pack voltage. When I am at home, I use the PFC-30 charger off a 110 VAC outlet turned down to 8 amps, to charge overnight.

The PFC-30 is the best of all worlds and you never have to worry about drawing too much current from an AVCON.

05/04

I removed the dual pro chargers. After much research, their 10 amp rating was only on a severly depleated battery (beyond normal). There rated value was much less than the actual output on a safely depleated battery.

On a normally completely depleated PbSO4 wet cell battery the dual pro charger output rated at 10 amps only put out 6 amps, and only when the AC input was 115 VAC to 120 VAC. This 6 amps quickly dropped to 4amps as the battery's surface voltage rose. So, really their 10 amp chargers are only 4 amp chargers.

Also, the dual pro chargers did not work correcly with a low AC input (below 115 VAC). This makes them a finicky and picky charger to use (not worth my time).

Would I recommend the dual pro chargers? No. For the same money, Soniel chargers have a four stage charging algorythm, and some of their models will run on 110 or 220 VAC.

I am trying a new charging method that could benefit conversion EV owners. Several small 12 VDC chargers that are preset to charge a pack properly. No adjustments, thus no under charged or over charged batteries. Since most conversion use 6 VDC traction (or golf cart) batteries, they are charged by using two 6 VDC batteries as a 12 VDC string. In an attempt to find a convenient off the shelf charging package, I choose Dual Pro SE to limit the amount of AC current to not pop a weak 20 amp breaker. This should let me test the chargers on my 132 VDC pack. Since most conversions are 96 VDC they could use the 15 amp version called the standard Dual Pro charger (the SE is a 10 DC amp model).

I have seven 12 V strings in the rear of my EV, thus I am using a 4 bank (left) and a 3 bank Dual Pro SE chargers in the rear.

In front I have 4 12 VDC strings and the 12 VDC aux battery (to run the honk, lights and radio), thus I have a 3 bank and a 2 bank chargers. Since I have included the 12 VDC aux battery, I have twelve 12 VDC strings like a 144 VDC pack.

The Soneil charging curve graphic shows that they are a constant current type. A 5 amp constant current charger equals a tapering 10 amp charger.

After talking to the Dual Pro support staff, they feel their chargers are of a more reliable design than Soneil's high frequency switching power design (like a computer power supply). Yet, out of four Dual Pro chargers ordered, I had to use their three year warrantee, and had two of them replaced. While the Dual Pro SE replacement chargers arrived quite quickly, it did not instill the reliability that Dual Pro's support team had of their product (what happens after 3 years).

Yet, Soneil is an untested charger (I have not tried one yet). Also currently, the highest current output is 5 amps. Their package design is small and light (because of the high frequency switching) but their package is not sealed like the Dual Pro chargers. Dual Pro chargers are designed to be mounted to a boat to charge the group 27 trolling batteries. The case and cables are acid and water resistant. The Soneil chargers have a AC power cord that could come loose from vehicle vibration.

At this time, I know the Dual Pro SE chargers work. However, my US-145 batteries are 3.5 times the capacity of a single group 27 battery.

A 10 amp Dual Pro charger takes more than one day to fully charge my pack. If a person wanted to try
a Dual Pro charger, I would recommend the standard Dual Pro 15 amp charger which comes in single,
dual or three bank models. The lowest price I found was on ebay, but the Dual Pro reps said they give
a good price too by buying direct.