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Planing CanView and BMS+ conversion with lithium

Discussion in 'Prius PHEV Plug-In Modifications' started by Mr-plugin, Oct 27, 2011.

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  1. epa5epa

    epa5epa Junior Member

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    Congrats!
    You complete the new world record on the day of Christmas Eve. It's worth.
     
    #121 epa5epa, Dec 24, 2011
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  2. Flaninacupboard

    Flaninacupboard Senior Member

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    John, there's lots worse you could have spent the day! I wish i was actively working on a project on the car, it looks like you are having a great time really :)
     
    #122 Flaninacupboard, Dec 25, 2011
  3. Mr-plugin

    Mr-plugin Member

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    Well I final hooked up the battery pack and went for a Drive on X-mas eve. I took it for a 17 mile trip partially in out of gas mode and some regular freeway driving to see how the battery performed. It was great. I drove in Ev mode first, then took it on the freeway. Even with the ECT at only 80 Deg. F. I was showing 255 MPG on my can view. I still do not have my BMS up and running so I can not do a full test yet, but looks very promising.
     

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    #123 Mr-plugin, Dec 26, 2011
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  4. Mr-plugin

    Mr-plugin Member

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    Here is a Pic with the Battery up for Spare tire access.
     

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    #124 Mr-plugin, Dec 26, 2011
  5. lopezjm2001

    lopezjm2001 Senior Member

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    Nice job. I do not like the idea that you have live 240Vdc parts which you can easily touch. In my system it is almost not possible to touch any live 240Vdc parts of either positive or negative polarity without using a tool. It is only possible to touch the anderson plug pins. So you have exposed live parts which could kill. You may want to consider installing your contactor and service fuse inside a PVC box (electrical enclosure) but still have the service fuse exposed so it can be removed without opening the PVC box.
     
    #125 lopezjm2001, Dec 27, 2011
  6. Flying White Dutchman

    Flying White Dutchman Senior Member

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    so you wheere doing this with out the bms+ connected?
    only the higher voltage of the add pack just like with the org calcars build? only now with a litium pack
     
    #126 Flying White Dutchman, Dec 27, 2011
  7. mrbigh

    mrbigh Prius Absolutum Dominium

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    Nice concept and build.
     
    #127 mrbigh, Dec 27, 2011
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  8. Mr-plugin

    Mr-plugin Member

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    I am going to cover it. I am thinking 1/8 clear polycarbinate. I will have to pastic weld a "box top" with side for the Battery pack. And cut another piece for the contactors. Just have not got to that point yet;).

    Not quite. My pack is only nominal 230v. The CalCars method required a higher voltage to shift the state of charge, with the disadvantage of high current being put into the OEM pack. The lithium pack is roughly the same voltage as the Oem pack and the BMS + changes the SOC signal to the ECM.

    Yes, but I kept a eye on my pack voltage on my CAN View screen the whole time. the pack even under 100amp load never went below 220v (over 3.0v per cell).
     
    #128 Mr-plugin, Dec 27, 2011
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  9. Mr-plugin

    Mr-plugin Member

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    If you notice I used the orange Disconnect from my spare Oem pack mounted to the left side of my lithium pack, which has the fuse built into it . I will keep it outside my clear cover so it can be disconnected even when lifting up the pack for the spare tire.
     
    #129 Mr-plugin, Dec 27, 2011
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  10. lopezjm2001

    lopezjm2001 Senior Member

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    Do you have a 100A fuse link which will split your 230V lithium battery in two if you get a short circuit directly across the 240V terminals before your Prius service fuse? You should be able to get one which replaces one of your battery links.
     
    #130 lopezjm2001, Dec 28, 2011
  11. planetaire

    planetaire Plug in 20 kWh 85 km/h or > 208km range

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    Thank you for the pictures, Mr Plugin. So you have 40Ah*72 cells, more then 9kWh ? :D

    When will you have your Bms ? What model did you choose ?

    Did you read the inrush current when connecting lithium on nimh cells ?

    :)
     
    #131 planetaire, Dec 28, 2011
  12. Flying White Dutchman

    Flying White Dutchman Senior Member

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    72 cells right? litiums are at 3,2 volts ( or your not? )
    so that makes 230 volts but when charged those are at a higher voltage right? ! 4 volts? making it higher then 230!?
     
    #132 Flying White Dutchman, Dec 28, 2011
  13. Flaninacupboard

    Flaninacupboard Senior Member

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    Charge voltage for LiFePo4 is usually 3.6V, so 259.2 for 72 cells. after a few seconds thid drops to resting voltage of about 3.35v, so 241.2V for 72 cells. under load it will drop further.
     
    #133 Flaninacupboard, Dec 28, 2011
  14. Mr-plugin

    Mr-plugin Member

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    I made my own Pcb's and I am using celllogs. I hope to have everything for the BMS done by this weekend. I did check the current the first time I turned it on. I was not able to measure the spike but with a full lithium pack and the OEM pack at about 120v, the current started at about 21 amps and quickly went down to 5-6 amps within 10-15 seconds, then tapered off. The pic I posted shows the large circuit board which has the alarm relays and the small board is a slave board.
     

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    #134 Mr-plugin, Dec 28, 2011
  15. Mr-plugin

    Mr-plugin Member

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    As Flaninacupboard put it, after charging the voltage drops and after applying a load will drop lower.
     
    #135 Mr-plugin, Dec 28, 2011
  16. lopezjm2001

    lopezjm2001 Senior Member

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    Thanks for the photo. Not a bad job with the BMS. I thought it has way too many plugs but then I remembered your username!! Are you using four slave boards? Do all you slave boards connect in parallel or series? I think the three pin plug is 12v supply and PHEV signal, correct?
     
    #136 lopezjm2001, Dec 29, 2011
  17. Flying White Dutchman

    Flying White Dutchman Senior Member

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    240 is a nice start voltage
    this seems to work/combine nicely..

    where did you get the cells and what did you pay for them if i my ask
     
    #137 Flying White Dutchman, Dec 29, 2011
  18. planetaire

    planetaire Plug in 20 kWh 85 km/h or > 208km range

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    Each slave board have a cellog that is powered by the 8 lithium cells on wich it is connected.

    You add a relay on each slave board drive by cellog alarm pin.
    Will you energise each relay by the same 8 cells, so 23-28v ?

    Did you test one cellog during driving, with an important amperage, say more then 50A or less then -50A ?
     
    #138 planetaire, Dec 29, 2011
  19. dan2l

    dan2l 2014 Prius v wagon

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    Hi Mr-plugin,
    Looks like relays to turn off the system based on CellLog allarms but no active balancing. Is that true?

    The PacificEV system adds a 7ohm resistor comming on at 3.6v for each cell to balance at the top. Your system is fine, but it requires you to balance manually as needed.

    Thanks,
    Dan
     
    #139 dan2l, Dec 29, 2011
  20. Mr-plugin

    Mr-plugin Member

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    To some up the BMS. The master board has 2 connectors on the left. 3 pin has 2 power inputs (one 12v key on. one 12v from a/c power source when charging). then ground. left bottom 24V input from 8 cells. Right side of master top plug alarm signal in series. bottom right plug. 2 alarm 12v, outputs one latching for charger and one non latching. The slave board left top alarm series, left bottom 24v input 8cells. right connector series alarm.

    I did use a lot connectors, but I do not like screw terminals and if I solder every thing together then if I need to change something it would be a pain. I will do this if I have connection problems.
     
    #140 Mr-plugin, Dec 29, 2011
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