Grid charger test adapters |  | | | Test adapters |
I realize that many people would like to see if the chargers can "fix" their pack, before they go through the expense and labor to install it in the car. The tests adapters offer a way to do that.
I have designed a safe and easy to use system that allows you to do that.
The positive HV test probe with spring hook, the #8 to 1/4" ring adapter for the negative, and the fan plug, allow the charger to be used for charging a pack without requiring the full install, or any removal of the pack.
The adapters attach to the harness that would be used for the car, so you can just send back the test adapter components for a refund minus a rental fee.
If you decide to send it all back, there will be a small restocking fee if the charger is returned in like new condition.
To order a charger and harness, use the pricing on the grid charger blog, just as you would to buy the charger, I will also require all the legal documents and order form.
If you return the charger, you will be responsible for getting the charger back to me with all of the accessories and components, in like new condition. I will charge a restocking and inspection fee of $50, and refund the rest of the purchase price, minus the shipping.
On the test kit, I will charge $100 for the Insight test kit,and $135 for the Civics, plus the actual to be determined shipping charges. The Insight test kit will fit in with the charger so there is no cost for the shipping, but the civic kit with the test fan assembly will require a separate shipment.
If you decide to return the test kit in like new condition, I will refund $75 for the Insight kit, and $100 on the civic kit with fan.
If a harness is ordered with a test kit, the PTC and fan boards on the harness will have the fan cable and PTC bypass resistor already installed, and a 2 pin fan adapter.
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Attaching the test probes to the insight harness
|  | | | test adapters on Insight harness |
The probes attach to the hearness HV+ and - harness ring terminals with the included #8 pem stud and nut.
The PTC input of the temperature board requires a 20 ohm resistor across the terminals.
The temp probes should be taped together so they are at the same temperature. The probe to harness connections should be slid into the short wire loom, and then taped up to insulate and support the connection. The negative lead is attached and insulated the same way. |
Attaching the test probes to the insight battery pack
|  | | | Attaching the test leads to the insight pack |
The +HV probe clips on the big resistor as shown. the negative attaches to the big top negative terminal. |
Attaching the test probes and test fan to the first generation civic harness
|  | | | Attaching the test probes and test fan to the first gen civic harness |
The probes attach to the civic in the same fashion as they do to the Insight harness.The 20 ohm resistor is required on the PTC extension cable Probe side as shown.
The fan cable red lead attaches to the +12V terminal of the fan board, and the black to the ground. The plug mates with the plug on the test fan.
Add some weights to bots sides of the box to assure a good seal, so the pack is adequately cooled during the charge. |
Attaching the probes to the first gen civic battery pack.
|  | | | Attaching the test probes to the civic pack |
The + HV probe attaches to the aluminum buss bar as shown, the negative to the big negative terminal.
The test fan plugs into the fan test cable, and should run during the charge. Add some weight to the box on both sides of the fan, to assure a good seal. |
The civic battery cooling system
|  | | | Air path on the civic IMA |
The civic pack requireds the IMA cover behing the seat to be closed, as the blower evacuates air from the sealed box, and replacement air is drawn in the duct in the rear window well, and is drawn through the pack.
When the IMA box is open, which is required when doing a test charge, the air is drawn into the IMA box everywhere , so no air is drawn through the pack. The test fan draws air up through the pack, so the pack is properly cooled. |
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