Planing CanView and BMS+ conversion with lithium

Damned. The contactor is dead.

Welding would say that you had a high amperage during opening or closing the N°3 main relay. So an important voltage difference between nimh and lithium ?

Is it possible ?

 

at the time is justed returned from driving my pack down.. so it was no higher or lower then nimh
the litium pack was depleted.
but then i did my canview relay 2 EV disenage mod and during that time the lituim could have gone up.
and i did turn the prius on with the litium already connected ( you get a DTC that i cleared before when i forget ) and then turn prius in ready mode
only this time i got this problem.

i think its the mistake of having the litium pack manually connected for testing then turn the prius on instead of turn the prius on and then manual connect the pack.
lett the prius oem contactors close and then close your ev200 whats normal but i did not have my ev200 connected yet and do a manual connect where in this case it was already connected
i did make that mistake before but beside a DTC that i can clear there was no problem and in those cases i got the pack charged and not like now discharged.

EDIT

apartenly the prius got a turbo ;-)
P00B0 : GenericType DTC Powertrain - Fuel and Air Metering - ISO/SAE Controlled
Description
Turbocharger/Supercharger Boost Control "B" Module Performance

and for P0015
"A" Camshaft Position - Timing Over-Retarded

both are the cause of the relay stickking ( i hope )

its also funny because this sticking makes the prius do strange stuff

like when i shutdown the prius when i found out this dtc was set the ice spun up and then instead of just stopping it free wheelt in rpm down after i shut down the prius.
maybe that because its in a safe state running a different software settings when a DTC like this one is set

in a few hours i will now.. then i hope to have my new main relay in.

EDIT

i found these !!


http://www.waffenschmiede.at/home/d...ypage_images.tpl&product_id=51&category_id=64

and these

 

FIXED ;-)
no more DTC

now to get it all back together

 

FWD made the mistake of letting one of the Prius SMR relays close under high current which led to the contacts being welded by the arking as they opened and closed. Probably several times. The Prius SMR relays are not designed for breaking high current under normal operation.
Another safety is to use the Prius ready signal to the Canview relays and not the 12v accessories or permanent 12v signal. The ready signal comes on after all the relays have operated and NiMH is connected and the "ready" light comes on the dashboard. By using this ready signal it ensures that in the unlikely event of the Canview relay 4 sticking closed one of the Prius SMR relays will not weld as a result.

 

pica's

the broken one.

i have to add that i do not yet have the ev 200 contactors connected
this was during a manual by hand connect during testing.

after serverel 100km testing with the A123 battery pack that i am going to rebuild in 5 boxes you can see that the pruis oem relay was not getting overheated.. it looks fine beside ofcourse the internal welding what was my fault.

 

so all this time you drive until your low voltage alarms go's off and then you pull over to by hand unplug the lithium pack? and drive on in normal hybrid mode?
when it happend i was parked at home...

 

I cannot see any evidence of contact weld ??? I cannot see in the photos where the contacts make and break the current. If your contacts did not weld then the relay may have mechanically jammed but this is very unlikely as these are automotive grade. I am sure it was caused by the loose nut behind the steering wheel (joke).

 

haha its probably th lose nut in my head instead.
the pictures do not show anything really just fun to show how it looks inside.
i am unable to get the relay out of the housing more then on the pictures
but looking with a screw driver it seems that the lower part is protected by some kind of whit silicon pasta/plastic where its not possible to open that instead of cutting tru it.

EDIT

i made a 1 hour and 25 min video of the replacement ( thats the total non stop video and so time it took me incl breaks for a cup of thee and a small thing to eat/snack)
raw edited to 40min
i hope i wil upload this one soon.

 

Maybe something like this

 

Ohhh, that's a beauty !!!

 

nothing less then that

 

NEWS about A123 cells

A defect in A123 Systems' prismatic lithium ion cells can cause batteries to short out and prematurely fail. The company said it is confident that it has isolated the problem to a single automated welding machine at its Michigan plant, CEO David Vieau said during a conference call today.

An incorrect calibration of one welding machine caused a misalignment of certain components in a battery cell. That misalignment can cause a break in the electrical insulation and a potential short, Vieau explained.

Prismatic cells made in another location and cylindrical cells made at A123 Systems' manufacturing plant in China are not affected.

http://news.cnet.com/8301-11128_3-57...lty-batteries/

EDIT
and intressing picture of a A123 pouch!

 

ok here is the video from the main relay replacement
this is a raw edit

it took 1hour and 25 min but thats including breaks the video is down to 36 min.

prius main relay replace ( warming read description before do it yourself ) - YouTube

 

So you do not use the "tyco" style contactor on your PHEV?

 

Really 240 VDC is HV and Im searching google for DIY oh what else and "hybrid interface" okay.

 

There is also a lot of info in this forum which is scattered if you take the time to read up. Using the advanced search function helps to find relevant info.

 

Lopez, I'm wandering, what's your estimated total add on weight in your conversion?

 

did anyone look at the video or is it to long?
maybe i do a 4x speed version ;-)