G2 Prius Plug in Purchased....

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85turbo
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G2 Prius Plug in Purchased....

Post by 85turbo » Thu, 16 Jan 2014, 02:24

so... with MUCH thanks to Vincent aka BigMouse the plug in kit lives !!

it was a Mammoth effort over 2 full 8 hour days, and another 1hr or so on the 3rd day, but it's now all up and running.

here's a link to the thread i created on prius chat about the install.
i don't really feel like posting the entire thing again here...

click me


charging is at the full 25A into the pack. tested with a clamp on meter.
draws around 6-7A from the wall.

the first full charge today took 6.1kwh from the wall, which seems a bit high, given that it's a 4kwh pack, and it's an active PCF corrected charger that gets 98% power factor for much of the charge time...

have to monitor that and see what's happening. i was expecting maybe 5wkh but just over 6kwh...... ?

Jason.
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Post by BigMouse » Fri, 24 Jan 2014, 01:45

Awesome numbers you're getting there! Glad I could help. Once I get back from the US I'll tear apart the batteries you left and see what their condition is.

I've tested one of those same cells at my uni at 43Ah when new, so you've got around 4.4kWh installed. I think I remember that it draws 0.7A when running, which over 8hrs comes to 1.2kWh. The numbers seem to add up. You're probably putting 4.9kWh in to the batteries with about 85-90% efficiency from the plug. Not too bad.

I assume the charger does shut off eventually and the SoC meter is working as expected? If not, I'd get in touch with Rod and see what he says. He knows his BMS better than anyone.

Any update on the fuel economy numbers now that it's been a week or so.

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Post by 85turbo » Fri, 24 Jan 2014, 01:58

i havent been able to 100% confirm the charger shuts off completely, as i cant see the led on it, however even leaving it running for a full 12 hours after the current fell to 60 watts at the wall, there was no drop off in current draw.

so im assuming for now that the 60w is the fan itself, and maybe a little standby from the charger..

the Soc meter is working well, though i would like to mount it up front once you return.

first week of commuting (not a full week as yet) and im averaging 2.6L / 100km or 90mpg us or 108mpg imperial.

have consumed 13.2kwh from the wall to offset the fuel used.
overall i am stoked with the performance of the kit.

as a test, i want to remove the lid this weekend and charge the pack with the lid off.
that way i can see the shunt leds come on. if they all come on when the charger is still drawing the 60 watt figure, i will have my proof that the 60 watts is as good as it will get.

i have the charger on a 5hr timer. set to charge from 1am to 6am every morning.
this seems to be working fine, as each morning i get to the garage the Soc meter is full again.

how's the trip going Vincent ?

Jason.
Last edited by 85turbo on Thu, 23 Jan 2014, 15:01, edited 1 time in total.
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Post by 85turbo » Sat, 28 Feb 2015, 04:31

So.....

Long time since I posted anything here, kinda went back to being a lurker.

Anyway, I have an update.
The DC-DC converter in the system has failed.

I need to find someone (hopefully locally) that might be able to repair it.

There was no noises, no smells and no magic smoke was emitted.
But there is no current output from the converter.

Batteries, BMS and charger still fine.
Just the damn DC-DC.

I got a quote for a replacement unit shipped from China,
And it's a little out of my budget right now.

So until I can get it fixed or replaced,
I'm back to a regular hybrid getting 5.0L per 100
Instead of my more normal 2.2L per 100.

If anyone in the sydney area has any leads on a repair technician
I would be most greatfull.

Jason.
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Post by chris » Mon, 02 Mar 2015, 01:21

I have used http://indcontrol.com.au/ to repair a charger. They may be able to help.

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Post by 85turbo » Mon, 02 Mar 2015, 01:25

Thanks for the link. I will check them out.

Jason.
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Post by 85turbo » Sat, 27 Feb 2016, 17:24

Reviving an old thread here.

So, the story goes that the above vendor was unable to repair the converter.

I pulled the entire system out and have been running as a regular hybrid for the last 12 months.
I sold off the bits that were still ok (cells and charger) though on reflection maybe that wasn't a good idea ?
Given my new plans.

I'm now in a financial position to start getting back my PHEV status.
What I have planned is to get myself the plugin supply kit from the USA.
I will be buying all of the hardware (minus batteries, BMS and charger) around the end of April.
The the charger and BMS by the end of June.

Then the long save for the cells begins.

I will update this thread as and when parts arrive or are installed.

What I'm mainly here for this time, is to see if anyone in or around Sydney knows where I can get a battery box fabricated ? I want a lexan lid / top for it. For two reasons. One to show off the batteries to anyone that might be interested, and so I can physically see the cell modules lights. The main part of the box would have to be metal fabricated somewhere. As I lack the skill and tools to do one myself.

I have thoroughly read through the blog on evplus, and that's going to be my go to guide for most of the install.
I intend to copy most of what's been done there. Right down to the charger mount method he used.

Jason.
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Post by Greg partridge » Sun, 28 Feb 2016, 14:20

Geoff O Tool from GT Tooling should be able to make up the box.

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Post by 85turbo » Sun, 28 Feb 2016, 19:39

thanks for the contact.
i will contact him when im close to ready for the battery pack build.

went for a drive today in a plugin converted Prius today.
the car i was in today can run in EV mode up to 86kmh and for around 65km before running the ICE.

that's what i am aiming to replicate with mine.

i will update as and when things change.

Jason.
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Post by reecho » Mon, 29 Feb 2016, 15:22

85turbo wrote: thanks for the contact.
i will contact him when im close to ready for the battery pack build.

went for a drive today in a plugin converted Prius today.
the car i was in today can run in EV mode up to 86kmh and for around 65km before running the ICE.

that's what i am aiming to replicate with mine.

i will update as and when things change.

Jason.


Was the plugin your drove a plugin supply designed kit?

I do like the simplicity of those kits...just a contactor... Image

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Post by 85turbo » Mon, 29 Feb 2016, 16:55

The one I was lucky enough to go for a drive in wasn't designed by plugin supply, but it was a very a similar setup using a contactor to parallel the lithium pack to the STD HV pack and a SOC spoofer.

So basically the same idea. Just not exactly the same implementation.

Jason.
Last edited by 85turbo on Mon, 29 Feb 2016, 05:56, edited 1 time in total.
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Post by evric » Tue, 01 Mar 2016, 05:08

Hi Jason,
I would be interested to know the manufacturer / model of the conversion system used in the Prius you drove.
Eric
Prius Plug-in Conversion: http://www.evplus.com.au ...Holden Barina EV: http://www.evric.kestar.com.au

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Post by 85turbo » Tue, 01 Mar 2016, 06:17

It was a combination of a hybrid ecu spoofer and an arduino and a bunch of other systems.
The owner basically bought a systems from several different places and is running a system he built himself.

I will see if he will post here to give more info than I can give.
He has the same end result that the plugin supply kit has, but acheived in a different manner.

Being driven in his car was more than enough to convince me that I was making the right decision
to go back to phev with my car.

Jason.
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Post by lopezjm2001 » Tue, 01 Mar 2016, 15:17

85turbo wrote:I will see if he will post here to give more info than I can give.
Hi Jason,

You can find all my details of my PHEV conversion on Priuschat at these threads:

Priuschat - My PHEV Journey

Priuschat - My Duinomite Mega

Some of the AEVA members may remember seeing my PHEV Prius at the EV show at Canberra a few years ago "Thunderbox".

Basically I use:

1. 70S2P configuration of Lifepo4 A123 3.2volts 20AH Pouch Cells using the contactor dump method by EV Works and
2. BMS+ or BMS2 from www.hybridinterfaces.ca by Norm Dick as a SOC spoofer (no longer available but you can build one at Priuschat - Hybrid Interface 2013 ). Cleaner solution than PIS.
3. 5 x centralised Mini-BMS by Dimitri @ CleanPowerAuto . Centralised version no longer available.
4. EV Display by Dimitri @ CleanPowerAuto using Bluetooth Comms Device to communicate to CanView.
5. And also use Priuschat - ECT Spoofer by CCdisk
6. As a Canbus viewer (better known as CanView) I was originally using Duinomite Mega by Olimex and then upgraded to colour using CGcolormax2 by CircuitGizmos with a small VGA Lillyput screen.
7. Elcon 1500watt battery charger by EV Assemble

Last edited by lopezjm2001 on Tue, 01 Mar 2016, 18:08, edited 1 time in total.

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Post by 85turbo » Thu, 17 Nov 2016, 07:02

Hi all.
 
I need some advice and info on appropriate fusing for my new plugin system.
 
Some info for the new system:
 
76x 3.2V prismatic cells in series for 243.2v nominal 269.8V max
40ah cells.
 
The max load the pack should see under normal conditions is ‪150A‬.
As this is a hard limit in the Prius G2 motor inverter.
 
I have asked for info from a few places now and didn’t like what I have been told.
I need info on how many fuses I should run, and where they should be located.
 
I will obviously need a main fuse close to the Positive lead on the pack
(all cells are in one location in the car, and are wired in 4x series strings of 19 cells)
Need a recommendation for the right type and size, plus a holder for that fuse….
 
Should I have one fuse for each string, even though they are all in the one location ?
 
And I need recommendations on where to get said fuses ? and suitable holders….
 
Below are some of the questionable answers that I was given.
 
One place said I should use an ANL fuse mid pack, rated slightly higher than the main fuse.
When I checked, these ANL fuses were rated for 32V DC only….
 
The plug in system supplier has wire fusible links between the strings of cells. Where the wire is acting as a slow blow fuse…..
Attached is a pic of that….
I'm not sure I really like that idea.


 
 
Any advice greatly appreciated.
I have ordered the batteries and paid a deposit.
I should have them late January (due to budgetary requirements and a holiday between now and then)
 

Jason.
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Post by coulomb » Fri, 18 Nov 2016, 03:44

85turbo wrote: I will obviously need a main fuse close to the Positive lead on the pack
Not necessarily. The fuse(s) could be anywhere in the series string, including mid pack and near the negative or positive terminal.
Need a recommendation for the right type and size, plus a holder for that fuse….
It will need to be some sort of High Rupture Current (HRC) fuse, rated for at least 300 VDC.
 
Should I have one fuse for each string, even though they are all in the one location ?
DC fuses are expensive, and more than one for the whole string is overkill.

I'd consider up to three contactors though, or at least two, so that when not running, the pack is not much more than Extra Low Voltage (120 VDC). [ Edit: by which I meant that no two points outside a battery box have more than 120 VDC between them. ] To be strictly ELV, the pack should be broken into at least 3 strings (say 25, 25, and 26 cells; 26 cells x 3.6 V is 93.6 V). The contactors need suitable ratings, e.g. google EVC500 (very similar to the old EV200s, which are still available but much more expensive).
 
The plug in system supplier has wire fusible links between the strings of cells. Where the wire is acting as a slow blow fuse…..
If you mean the red wires in that photo, I believe that those are comms (digital or analog communication) wires for the battery management celltop units. Using thin insulated wire as a fuse is a terrible idea. It's a fire hazard, and it won't quench a DC arc.

For suitable fuses, check the usual EV suppliers, but also places like
https://www.swe-check.com.au/ .
Last edited by coulomb on Thu, 17 Nov 2016, 16:46, edited 1 time in total.
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G2 Prius Plug in Purchased....

Post by lopez » Fri, 18 Nov 2016, 04:22

Hi Jason,

Try looking at these. They are three pole but more affordable.
http://www.renewedenergy.com.au/nh00-fu ... tch-3-pole

Fuse rated DC 500V,160amps.
http://www.renewedenergy.com.au/nh-size ... -500v-160a

John

Hi John,
I fixed your links.
Eric
Last edited by evric on Thu, 17 Nov 2016, 18:23, edited 1 time in total.
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Post by evric » Fri, 18 Nov 2016, 05:13

Hi Jason,

If you are using the Plug-in Supply kit, the contactors come with the kit.

They use 2 contactors one in the negative line and one in the positive.
These are controlled by the PIS Rear Controller box.

Also the charger connection uses a contactor. (I used 2 on that as well, to ensure the charger was completely disconnected when not in use).

The fuse I used (in the positive lead close to the battery) is a BUSSMANN Semiconductor Fuse FWH-125A 500V AC/DC. (Search eBay for: FWH-125A)
Size: Total length 91mm x 31mm diam centre with 25mm x 5mm lugs suitable for 8mm bolts.

Image

These fuses were from eBay (from surplus equipment)
I placed the fuse in a plastic conduit section (painted orange) with bungs in the end with holes in them for the wires.

In the negative lead I placed the 75mV shunt for the JLD404 meter to keep an eye on Ah etc.

Eric
Last edited by evric on Thu, 17 Nov 2016, 18:56, edited 1 time in total.
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Post by 85turbo » Fri, 18 Nov 2016, 06:07

evric wrote: Hi Jason,

If you are using the Plug-in Supply kit, the contactors come with the kit.

They use 2 contactors one in the negative line and one in the positive.
These are controlled by the PIS Rear Controller box.

Also the charger connection uses a contactor. (I used 2 on that as well, to ensure the charger was completely disconnected when not in use).

The fuse I used (in the positive lead close to the battery) is a BUSSMANN Semiconductor Fuse FWH-125A 500V AC/DC. (Search eBay for: FWH-125A)
Size: Total length 91mm x 31mm diam centre with 25mm x 5mm lugs suitable for 8mm bolts.

Image

These fuses were from eBay (from surplus equipment)
I placed the fuse in a plastic conduit section (painted orange) with bungs in the end with holes in them for the wires.

In the negative lead I placed the 75mV shunt for the JLD404 meter to keep an eye on Ah etc.

Eric


Thanks for the info.
I believe I have followed your blog about your conversion. (Evplus ?)
I tried sending you a message and email about a year or so ago, but never got a response.

Can I please ask if you still have a template for the charger mount that you made ?
I intend to do exactly the same as you did, and a template file will make life much easier.

I have gone with a full BMS from EV-power in WA for the battery pack control and charge control.
I'll not be using the PIS battery management system. Other than that, my install will be almost the same as yours.

I may also need to have the charger disconnect when not in use.
Will cross that bridge if I have interference issues.

Can't wait till I get the system finsished.

Jason.
Last edited by 85turbo on Thu, 17 Nov 2016, 19:10, edited 1 time in total.
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Post by evric » Fri, 18 Nov 2016, 06:14

Hi Jason,

Sorry about the no reply - I don't understand that - I always reply.
The template is a cardboard cutout, there is no file.

Eric (EVPLUS)
Prius Plug-in Conversion: http://www.evplus.com.au ...Holden Barina EV: http://www.evric.kestar.com.au

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Post by 85turbo » Fri, 18 Nov 2016, 06:27

evric wrote: Hi Jason,

Sorry about the no reply - I don't understand that - I always reply.
The template is a cardboard cutout, there is no file.

Eric (EVPLUS)


No problems.
Don't know why I didn't see any response.

I tried a SMS to the phone number on the blog, and a reply to the blog post too.

Not a big deal.

Shame you don't have a file that you could share for the charger mount.
Guess I'll just have to do the same as you did. That's what I was planning to do anyway.

I have installed all of the hardware for the PIS system now (with help from John)
I have the rear springs and new struts waiting to be installed.

im planning to mount the charger and do the rear suspension upgrade in January while I'm off work.
Then when the batteries arrive in late January, all I have to do is get a box made and finish the install.

I have posted pics of what has been done so far on Prius chat.


Jason. Prius chat post
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Post by evric » Fri, 18 Nov 2016, 07:04

Hi Jason,

I noticed that you are using the EV Power blue box BMS controller.
Why, when the PIS Rear Controller has all that functionality built in?

Eric
Prius Plug-in Conversion: http://www.evplus.com.au ...Holden Barina EV: http://www.evric.kestar.com.au

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Post by 85turbo » Fri, 18 Nov 2016, 08:06

Because I wanted a display of volts and AH and percentage of discharge.
Plus I have a feeling that the EV power unit might be just a little better at protecting my expensive battery pack.

I know I could have saved some money by not using the unit from Rod, but it was just a personal call.

The biggest reason was that I wanted the display up front near me when driving.


PS, what has your longer term experience with the PIS system been ?
When I had the enginer system previously installed, I was able to get 2.2L per 100km,
So I am expecting much better from the PIS system.

Jason.
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Post by evric » Fri, 18 Nov 2016, 14:26

Hi Jason,

The EV Power BCU looks great.

I have now updated my blog (Battery Construction section) with the fuse and shunt mounting detail.(see EVPLUS link in the signature below)

Our long term experience: My wife drives this Prius every day going south of Adelaide (hills and fast) to our 3 grand children down there and north of Adelaide (fast) to our other 2 grand children. She never uses the KILL ICE switch and we are getting a long term average of 2.7L/100km. I get to drive it on the weekends and then often use the ICE KILL switch.
If the car was mainly used on the flat, and with me driving, I would expect figures in the 1.x L/100km
Eric
Last edited by evric on Fri, 18 Nov 2016, 03:30, edited 1 time in total.
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Post by 85turbo » Fri, 18 Nov 2016, 16:53

Great to know what to expect.

My work commute is 38km round trip and mostly flat.
So the plan is to run in ice kill mode all week.

And use blended mode for longer trips on weekends and holidays.

I'll have a look at the updated info on the blog.

Thanks again,
Jason.
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