I have finished making these little boards. They "watch" the Battery Management Systems in each pack (12 of them) and tell me if something goes wrong. The red sleeved ring terminal goes the battery pack positive, the spade terminal goes to the modified Headway BMS. The bright blue LED is mounted through the side of the battery pack.The LED will go OFF on any pack that signals a fault. I can keep driving then get out when convenient and check which pack has let me down. The board electrically isolates the packs from an alarm system (opto-couplers) that will tell me if there is a fault. As mentioned previously, all this is because the 48V packs were never designed to be placed in series to make a higher voltage system. These boards take a 12V input to enable them so they do not draw any current from the packs when the car is not in use. The 12V signal is also used to reset them if a fault occurs (off then on again) - after I have had a look at the LEDs of course.
The one in black is a finished unit which will now be installed in a battery pack. The uncovered board shows how I stopped the component leads from piecing the heat shrink (after I made 2 and had this problem). Basically a cut-up folder cover is placed on the back of the board then heat shrink covers it all.
The lead entering the photo from the right shows the four pins ready to go through a cable gland in the pack then be plugged into the connector housing that is them wired to my little monitor "bus".
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