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3KW EV Conversion - Plug In Supply

Discussion in 'Prius c Accessories and Modifications' started by Jeremy Nelson, Sep 10, 2012.

  1. Jeremy Nelson

    Jeremy Nelson New Member

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    Good news guys. I have ordered the battery parts - I am going with 64 lithium LiFePO4 15ah cells from Headway. Also had to purchase 64 Bm cell boards for battery management which I purchased from Plug-In Supply since I like how easily you can bypass a bad cell with their layout (thinking about the future if I need to replace any).

    I hope to get these items next week and be putting together the battery. The EV portion of this has still not been completely figured. When I pull the EFI fuse I get the car into the mode I want (limp-mode?) but there is a terrible beeping and the screen is flashing to pull over. Although I can live with this and even disable the beeping, apparently this is NOT the best way to get a limp-mode and the way to do it properly (no beeping, flashing, or errors) is to interrupt power somewhere else. I may have to open behind the glove-box area to get at where I need to, but I'll tackle that once I've got the battery in and working.
     
  2. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    To all who are following this, I highly recommend reading the Plug in Supply DIY post in the Gen II forum (in its entirity). My experience with them was terrible but one person has reported a positive experience. I would advise reading all you can (positive and negative) b4 making your decision. I cannot recommend this company to anyone due to my experience with it. I'm betting Jeremy will not get his batteries next week but, maybe I'll be proven wrong.
     
  3. actiondonkey

    actiondonkey Member

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    I would be a buyer at <= 3k should a proven kit become available.
     
  4. Flaninacupboard

    Flaninacupboard Senior Member

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    Jeremy,

    You should not need to pull the EFI fuse at all. The purpose of the controller PIS make is to encourage the car to run in EV mode as much as possible without setting any error codes. It's unclear exactly how it achieves this, but we know it broadcasts "something" onto the canbus network to increase battery usage and decrease engine usage. 72mph full EV mode is probably an unrealistic expectation (especially from 15ah cells), but certainly running at low speed will be almost all EV, and once you've used the gas engine to get up to high speed you will be able to cruise in EV. Gas use won't be zero, but it will be greatly reduced.
     
  5. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    I haven't heard of one person with any PIS kit that has been able to achieve above 52mph in full EV. The Prius HSD limits max EV speed to 52 but PIS claims 70+mph. Supposedly there is an updated hardware that is available to allow for this. It was supposedly designed by Kietty and has been tested. I have read (on this forum) that PIS customers have been told they will receive the updated hardware in the future but none have reported receiving it. It is my opinion that the hardware allowing this doesn't exist. If it does, I would think there would be several people wanting to brag about it and posting here or other eco modding sites.
    If it sounds too good to be true, it probably is too good to be true. I'll stand by the old adage of Ronald Reagan "trust but verify".
    I really don't want to see anyone else taken advantage of and lied to by PIS.
     
  6. MJFrog

    MJFrog Active Member

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    Jeremy,

    I believe I'm the one usnavystgc referred to regarding positive experience with PIS. Since you seem to have already jumped in for the kit, I'm not about to try to discourage you...just caution against too high expectations. Please read my GENII 4kwh (pretty much the same kit you've ordered) install thread: PIS 4kwh PHEV kit assembly and installation odyssey | PriusChat You'll want to especially read the battery build posts since you'll be getting into that shortly.

    I'm just about to finish my second tank (in the next week or so) after putting the kit into service in early July. On my first tank, I got ~135 mpg. I consider this somewhat low for what it is capable of, but that's because I ran out of charge and had to drive a couple somewhat extended trips in HV mode instead of EV. If I had the cash, I would have gotten the 10kwh pack instead and been much better off. Unfortunately, like you, $$$ rules and I got what I could afford.

    Some things to be aware of:
    • with a 4kwh pack you are NOT going to be doing any extended driving in EV at highway speeds. I have been able to travel 8-10 miles using a combination of gas and battery (get well over 100 mpg doing it), but anything less than a 10kwh pack will not get you highway speeds using pure EV for more than a few miles.
    • I can truthfully say I have driven up to 47 mph, all electric (in OOG mode). The roads here are fairly flat and that is an important factor! BTW, the fuse only needs to be pulled out for a short time, then reinserted. The beeping and squealing will stop when you put it back in. I use a ScangaugeII to clear the codes.
    • If you try to accelerate too fast, the pack voltage will drop VERY quickly and the kit will eventually shut itself off. The pack isn't depleted, but needs to 'rest' for a bit to recover from the abuse.
    • My daily commute consists of just over 17 miles, with ~4.5 miles @45mph and the rest around 35mph. When I arrive at work (or back home) and charge, I put in between 3.2 and 3.7 kwh according to my Kill-O-Watt meter.
    I've been driving almost all of my current tank in OOG mode (manually pull/reinsert the fuse--I haven't been able to get my remote switch to work) and here are my stats as of this morning...remember that 90% of these miles are daily commute per above.
    Last fill-up: 8/7/2012
    Distance traveled so far: 1847 miles
    Gas used (per Scangauge): 8.05 gallons
    Average mpg: ~230 mpg

    I have had to make only a few hwy trips this tank with the electric assist instead of all-electric, so my mileage is much better. In a year or so, I may have enough $$$ to add another 4kwh of battery, and be able to drive more on the highway.

    Good luck.
     
  7. bisco

    bisco cookie crumbler

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    there's a guy in the pip forum who claimed he was going to install the first pis for pip right after 09/24. we're all hoping he pulls it off, no word yet.
     
  8. Jeremy Nelson

    Jeremy Nelson New Member

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    MJFrog,
    Thank you for this information and it is very nice to hear something concrete from someone that has gone through this. I already knew that I wasn't going to be doing any driving on the highway in all electric because of the steep voltage drop. The importance of top speed for me is in regards to how much power there will be so I can start from a dead-stop at a light and not get honked at.
    I suspect that the Prius C will have a higher top speed in all-electric than the GenII. First of all I have taken the back seats, spare tire, and frame out to be replaced with a lightweight platform, so right there I'll see some savings. Also my experience with this car tells me this. The last time I pulled the fuse for all-electric I ramped it up past 48MPH, but had to stop. The first time was 8 months ago when I ran out of gas and gunned it on a flat space just for fun and reached 57 (if I remember correctly). If the factory pack had remained 100% charged I expect even more than that but this is only because I suspect Toyota has adjusted the limits (for example with a full pack you can engage warp stealth at 73MPG with the C). If I'm wrong oh well high speed is not my primary concern and I apoligize for misleading anyone. Proof in the pudding as they say?

    usnavystgc,
    Actually I'm not concerned about the PIS shipment. However the headway batteries are a problem now because apparently China is on holiday until Oct 5th? So basically they took my money but my order only shows "in processing" until they come back, and who knows how long it'll take to ship after that (they said 6-8 days).
     
  9. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    That is the exact same excuse I was given by PIS when my batteries didn't show up for a long time. "Oh, China is on holiday". I predict many more timeline promises will be made by PIS and not met. I predict you will be told "you'll get it next week" and next week will come with no shipments. If this is okay by you then, no problem. I just personally doing like doing business that way.

    Here's what my email said (just FYI)
    Dear Robb,

    How ar eyou?

    Now we are all in holidays, I will be back to work on 6th, April, I
    will send the updated information to you.

    BR
    Victoria
     
  10. Jeremy Nelson

    Jeremy Nelson New Member

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    usnavystgc,
    You are misunderstanding, the batteries are shipping directly from www.evassemble.com, so the excuse is coming from their live-chat support. My experience with PIS so far has been better than I hoped. But I also bare in mind that this is a small business, so I do expect some delays in response, and even shipping, but I always remain reasonable because I know I'm dealing with a busy person and not a big company with 100+ employees and a stockpile of product. I'm sorry your experience was poor, but you may be doing a diservice here since I will end up successfull and the alternatives to PIS are poor.
     
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  11. Flaninacupboard

    Flaninacupboard Senior Member

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    Yeah it is Golden Week in China!
     
  12. Mik1

    Mik1 Member

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    Jeremy, everyone wish you best of luck with your project, but you don't need to be so offensive if people have different opinion (read bad experience) about some companies and they want to share it with the others. If you want to have this thread as a one man show, then go for it and ignore everyone who you don't want to hear from in your thread. I can even tell you how to do it. Click on the profile picture and then when the new window will appear click ignore.
     
    usnavystgc likes this.
  13. Jeremy Nelson

    Jeremy Nelson New Member

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    Alright Mik1, you're right.
     
  14. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    What the heck is a grip?
     
  15. Jeremy Nelson

    Jeremy Nelson New Member

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    I meant gripe. Anyway I edited that post because I got offended myself and was rude for no good reason.
     
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  16. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    Well, sometimes we post b4 we think. I have done it too but I try to avoid it now. I appreciate the change in tone. Good luck with your project. I will bow out of this one and let you do your thing. I was never trying to discourage you. I was only trying to let people know that things aren't always as they seem.
     
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  17. Jeremy Nelson

    Jeremy Nelson New Member

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    Anyway the BMS Cell boards arrived from PIS. There was also a black cable which I think is for the EV kill switch, and some particle boards for mounting the BMS cells to the battery. Still waiting for the batteries from evassemble. They finally sent me a fedex tracking number so hopefully it'll show up the end of this week or beginning of next.

    However I don't have a charger yet, and will need some money before getting one. In the meantime I'll need to work these issues
    - Soldier and connect all battery parts and build enclosure for the pack.
    - Identify and connect to Prius ready-wire
    - Identify and connect to the ground-wire for the car computer for a EV kill switch.
    - Build platform for holding the battery/charge in the back.
     

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  18. bisco

    bisco cookie crumbler

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    thanks jeremy! all the best. fyi, the gentleman with the pip has his installed temporarily and it is working great. giving him about an extra 14 ev miles.
     
  19. Jeremy Nelson

    Jeremy Nelson New Member

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    That's great to hear bisco, 14 miles would be just enough for me to get back and forth from work on the cheap. My goal was 12 or better.
     
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  20. Jeremy Nelson

    Jeremy Nelson New Member

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    What a great car the Prius C is! I just got 76.7MPG for a 12-mile trip (not my normal MPG, I was pushing to see how much I could save)

    The lithium batteries arrived. Before building the battery pack, PIS's instructions call for balencing the cells by connecting all the negative connections together, then the same for the positive. I suppose this is so that whatever small charge is in the batteries can be averaged out between them, allowing for slightly more charge since they are all synced.

    A small issue is that evassemble only provided enough metal peices to connect the positive and negative for 34 cells, meaning I'd have to balence half of them at a time. It made more sense to me to balence all 64 cells at the same time, so took it upon myself to use a copper wire to connect all the positive connections. I would wrap it around one cell, tighten the screw, then wrap it around the next, all the way down. So long as the electricity is passing between all 64 both negatively and positively, I may have saved myself a few % charge. I left it this way for about 28 hours then disconnected everything. They should be balenced now.
     

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