First Enginer PHEV install in the Portland Or area, Gen2

Hi Dutch,
The "pic" is in the 1-30-2010 post. Did you not see that? If you have questions about that picture, Please be more detailed in asking those questions.

The initial install is simple. Just unplug the DB8 and plug in the CellLog. Same connector same pin out. However you probably want both the CellLog and the DB8 so you need to make up junction wire harness as I did.

I am told not to plug in the USB while the CellLog is connected to the Enginer cells because the USB power line is not isolated. So I pull the CellLogs out to down load them.

I have now added alarms to the CellLog alarm output. That connector has a black wire and a red wire. The black wire is connected to Cell 1 negative terminal. The red wire is switched with the alarm. I bought two 12v buzzers at Radio Shack. They are high enough resistance to stay under the 500ma spec for the CellLog. So the CellLog red wire goes to the buzzer black wire and the buzzer red wire goes to Cell 4 positive terminal. In this case the CellLog Black wire is not needed.

The software is very difficult but usable with the instructions included. I download the data into the supplied software and then save to XLS. Then I can manipulate it in Excel.

Thanks,
Dan

 

Hi Dave,
The Enginer system only does about 5 miles in constant EV because the 10amps does not keep up with the EV needs. The weak cell will easily do this.

I live out in the country. So I do about 1 mile solid EV. Then down a steep hill that does Regen to get me back up to 7 bars. Then 50-55mph for 4-5 miles before I get to town. At this point the Enginer system has been on for about 10 minutes. Note that the Prius HV battery stays at 7 bars for this whole time because the ICE is running. Most of this drive is still at 60+mpg because of what you call Freeway Boost. The system voltage limits when the Prius is at 7 bars so the current is only at 10 amps about half of this time.

Then, in town I can do about 4-5 miles of Pure EV. During this time the system is at the full 10 amps. The Prius HV battery drops from 7 bars to 2 bars and then the ICE comes on.

At this point I am heading home and get the speed back up to 50+mph. I get 40-50mpg until the Prius HV battery gets back up to 5-6 bars and then the mpg goes back up. Then back up the hill at low mpg. Finally the last mile is again all EV.

This total is about 15-20 miles total including the 1+5+1 miles of pure EV. The system accomplishes this even with the weak cell.

Hope this addresses your question.
Thanks,
Dan

 

Hi Dave,
Yes, you would need gas but not much.

If this is in your 2010, EV only works up to 25 mph. So anytime you hit 25 you get kicked out of EV. The first time this happens the ICE will do its warm up cycle. After that you can use a light peddle to keep the ICE off up to 45mph but you will not be able to accelerate without firing the ICE. So I expect you will run the ICE maybe a mile or so. You should still get 90+ mpg.

When you hit stop and go, you will be able to go farther in EV. So you may be able to keep the ICE off in the afternoon If you charge up the Prius HV battery before you start home. To do this the car needs to be on and in EV mode with the Enginer system on before you start to drive. This takes about 6 minutes per bar. So if you get to work at 3 bars. A 20 minute on time will get you started home with about 7 bars. By the time you get home you will be back down to 3 bars.

Here the problem is not the cell capacity but rather the transfer rate of the converter. The converter is limited to 10 amps.

If you want maximize EV I would suggest 6kwhr and 2 converters. Chan may be a better person the tell how that would work.

Thanks,
Dan

 

Hi Dave,
This is a very interesting topic. I think you may want to start a PHEV vs Pure EV thread to discuss it further. I have a comment on that but I will wait for the new thread.

Anyway this thread is not the best place for that discussion....
So :focus:

Thanks,
Dan

 

Hello Everyone,
Today I got 2 replacement cells from Jack to replace my weak cells. This means taking apart the battery pack, so I will do the more robust Buddy Cell process with heavy copper straps.

I was asked somewhere to publish pictures and document the process. I think that the best place to do that is in the thread called

Balance at the cell low voltage limit
http://priuschat.com/forums/prius-p...s/75115-balance-cell-low-voltage-limit-4.html

I plan to add the heavy copper straps.
I hope to do a cell capacity check and to pair the cells so that all pairs have as close as possible to the same capacity.
I hope to get a better balance at the bottom.

Thanks,
Dan

 

Hello Everyone,
I have completed my install in the Gen2 so I wanted to finsh this thread. However this may not be the first in the Portland area, Gene now has a Gen1 running.

I got the Feb kits and that included a Gen3 kit complete instead of a Gen2. So Jack sent me a Gen2 box and I rebuild my old system into it. So I now have the following.

32Cells paired and balanced as discribed in the balance at the bottom thread.
The original charger set for 57v at the factory.
A new Converter putting out 12a.
The old set of DB8 balancers
The old toggle switch and LEDs in the dash
A new bumper plug.
I have added a pair of CellLogs and Sirens for full obnoxiusly loud alarms

I am now charging without alarms. The highest voltage seen on any cell was 3.6v.

I drove 24 miles with an average of 95.9mpg. This improved mpg is because the I had changed converters. I had ordered a spare and so I put this one in just because I had it. The old converter put out 10a and the new converter puts out 12a. I may see more heating and so I may want the old converter in the summer.

I now feel like this system is ready to be used as "Plug and Play".

Thanks,
Dan

 

Hello Everyone,
I have now driven the rebuilt system for a week or so. I am always above 80mpg with each trip being over 20 miles. I have not yet run the system to a low SOC so I do not really know my capacity.

I typically start with 7 bars on the Prius. I leave the house and do 1 mile of pure EV. Then a 1/4 mile above 35mph which turns on the ICE. Then 1/2 mile of coasting with a steep down hill. The ICE is on during this 1/2 mile coast time. At the bottom of the hill the ICE temp is above 90degF and the ICE turns off at the stop sign. At this point I am still at 7 bars and have a reported average of 70mpg. Then I do 5 miles at about 50mph with 2 stop signs. At the end of that I am still at 7 bars and have a reported average of 80mpg. Then I do mostly EV in town. I get the average up over 99pmg but the SOC in the Prius goes down to low levels. If I can stop at a store and leave the Enginer system on then I can keep going on maximum EV for a while longer but the ICE temp continues to drop. When the SOC gets to 3 bars or the ICE temp drops too low, the ICE comes on and the mpg starts to drop. Going home is the reverse, 5miles at 50mph then up the hill then EV into the garage.

To get 80+mpg takes really knowing your car and where you are driving. Low SOC or low ICE temp will quickly drop your performance.

In another week of so I will post a chart of my mileage.

Thanks,
Dan

 

Hello Everyone,
I am still running with no problems. I am still getting high mileage here is my chart.

I have always used the Prius average numbers. I know this may not be fully acurate but it is good for comparison. I was getting 45mpg before the Enginer install and that is what I compare to.

I do not have a ScanGauge running in this car. In my Wifes 2010 the ScanGauge matches the Prius reported mileage exactly.

Thanks,
Dan

 

I do not recommend it. I have seen 80a drawn with one 3k converter and cells just above the 46v limit. So the would be as high as 160a through 2 converters. The cells will droop their voltage a lot with this current draw.

Also the Prius will throw codes with 2 converters.

Thanks,
Dan