grid charger/balancer - Page 13

retepsnikrep · 06-19-2009, 01:25 AM

Quote:

Originally Posted by Mike Dabrowski 2000

The second diode just adds a second level of protection on the other lead.

So if you imagine the diode in the + lead failed short circuit, then you grabbed the + wire and the neg wire, you still would not get shocked, as although you would be at +144V you could not complete the circuit to the neg due to the diode in the neg lead only allowing power to flow in the other direction.

Ditto if diode in neg lead failed in same way and you grabbed both leads, you would be at 0V but you could not complete the circuit to the +144v due to the diode in + lead.

If both fail short circuit and you grab the leads then you are in trouble! Even with all the safety you should still use normal HV procedures and techniques.

aisbell · 06-26-2009, 07:14 AM

My Insight is on its way to Sweden from Honolulu. When it arrives in early August, it will not have run for about 2 months, so self-discharge may have increased the imbalance among the individual cells. I would like to be able to attach a grid charger/balancer to my IMA battery shortly after my Insight arrives to avoid any possible battery problems.

Has a "recipe" for a grid charger/balancer been finalized? I am capable of doing the actual grid charger/balancer building and installation of the necessary attachment to the battery itself (I think), but I have no idea where to buy the necessary parts. Can someone please assist me in finding the necessary parts in Europe and preferably in Sweden?

**Hybrid-Battery-Repair** · 06-26-2009, 03:57 PM

Quote:

Originally Posted by aisbell

My Insight is on its way to Sweden from Honolulu. When it arrives in early August, it will not have run for about 2 months, so self-discharge may have increased the imbalance among the individual cells. I would like to be able to attach a grid charger/balancer to my IMA battery shortly after my Insight arrives to avoid any possible battery problems.

Has a "recipe" for a grid charger/balancer been finalized? I am capable of doing the actual grid charger/balancer building and installation of the necessary attachment to the battery itself (I think), but I have no idea where to buy the necessary parts. Can someone please assist me in finding the necessary parts in Europe and preferably in Sweden?

Jim,

You turned off the battery switch, right?

Leave it off after you get the car until you have had a chance to charge it.

aisbell · 06-27-2009, 05:20 AM

Quote:

Originally Posted by Hybrid-Battery-Repair

Jim,

I am the other Isbell, Art

Quote:

Originally Posted by Hybrid-Battery-Repair

You turned off the battery switch, right?

No. I decided not to stash any tools in the IMA compartment when my Insight was being shipped, so there was no risk of anything shorting. Also, the shipper drove my Insight into the shipping container and someone at the destination port will drive it out of the container, so I wanted to minimize the risk of it not starting. The 12 v. starter was used to start my Insight only when I had a defective MCM over 5 years ago. It seemed like a pretty wimpy starter.

Quote:

Originally Posted by Hybrid-Battery-Repair

Leave it off after you get the car until you have had a chance to charge it.

I could shut the IMA switch off before I drive my Insight from the port to my apartment if that would help. With the IMA switch off, I would be driving about 50 miles without the 12 v. battery being charged. In Sweden, headlights must be on when a car is being driven even during daylight hours, so I would risk discharging the 12 v. battery completely before arriving home.

However, I have no grid charger at this time and have only about 3 weeks to build one before my Insight arrives. That's why I asked whether a design spec had been finalized.

retepsnikrep · 06-27-2009, 07:10 AM

I would be tempted by three of these in series, in fact I might buy three to try them out. Would fit in a nice plastic enclosure with a fan.

If they can reach 55V out each that's 165v.

Or use 4 set at 45v out to reach 180V.

ebay 320337880727

Cheap as chips.

Or one of the above in series with one of these and job sorted

ebay 220345301746

Same supplier as well.

aisbell · 06-27-2009, 08:25 AM

Quote:

Originally Posted by retepsnikrep

I would be tempted by three of these in series, in fact I might buy three to try them out. Would fit in a nice plastic enclosure with a fan.

I would think that if someone on each side of the pond would assemble a proven grid charger/balancer and provide the necessary battery pack connectors and installation instructions, there would be sufficient numbers of Insight owners who would gladly buy this grid charger/balancer for a price that would make the time and effort spent by the assemblers worthwhile (hint, hint

**Hybrid-Battery-Repair** · 06-27-2009, 09:35 AM

Quote:

Originally Posted by aisbell

I would think that if someone on each side of the pond would assemble a proven grid charger/balancer and provide the necessary battery pack connectors and installation instructions, there would be sufficient numbers of Insight owners who would gladly buy this grid charger/balancer for a price that would make the time and effort spent by the assemblers worthwhile (hint, hint

You'd think - NOT!

I've been trying to find someone to assemble them for me. Every customer that I've asked has told me that they would gladly buy one from me to extend the life of their freshly built batteries. It's a natural because I can prewire their batteries.

Even the people that I turn away (either because they're under warranty or have a non-battery problem like a bad fan in a HCH) want one.

If anyone is interested in building them for me, please contact me directly.

aisbell · 06-27-2009, 09:49 AM

Quote:

Originally Posted by Hybrid-Battery-Repair

If anyone is interested in building them for me, please contact me directly.

At this point, I'd be happy with just a parts list and instructions detailed enough that I would have a good chance of success in assembly and installation. Maybe a proven design has yet to be perfected.

retepsnikrep · 06-27-2009, 11:38 AM

I've just given you the parts list! Just buy those two e-bay items.

Fit a diode protected socket to your pack.

Connect those two units in series with some safe connections, plug into your car and adjust output on the psu until output is 170v or so and limit current to 250-300ma using cc mode.

I now insist on fitting the socket to all battery swaps I do. I've got one on the bench at the moment reconditioning prior to being fitted in about 10 days or so.

I agree they should be standard fitment on all swapped packs and could easily extend usable life betwen full rebuilds many times.

JimIsbell · 06-27-2009, 02:16 PM

Yep, as he said, four of those set to 43.2Volts (minimum according to the specs) in series on the outputs and parallel in the inputs would do perfectly (172.8V) and cheap, if you are on the east side of the pond. That's the parts list. Then add a $2.99 Harbor Freight digital meter to set the current.

Unfortunately, the freight on four of those to the USA would double the price. Fortunately I already have a power supply ($50 on Ebay) that works fine and is fully adjustable. But even having one, I would spring for 4 of those baby's if the freight wouldn't kill me. They would look a lot better than my home brew setup.

The connector to the battery pack is as simple as some wire and an indexed trailer connector. Add two diodes for $1 a piece...if you are a sissy.... Personally I enjoy a smack once in a while to keep the heart muscle limbered up.

If these text based descriptions are not enough then you need technical help from a friend, like a Ham, or an engineer. He/She will understand these notes.