grid charger/balancer

[JimIsbell]

Need INFO!

I am currently putting my first refurbed battery through its paces on the bench and so far I am very happy with the results.

But, one thing has me confused. Are all the sticks identical and are the temp sensing devices NOT in the sticks? I cant see any difference in the sticks and yet I know that some have temp sensing and others do not. I have assumed that all sticks were interchangable. Are they NOT?

[E27006]

Four of the Sticks have a Thermistor attached, if you look at the wires coming out of the pack on the Junction Board end, you will see them, the wires have coloured sleeves, from memory Red- Yellow- Black- Green.

All 20 sticks are linked by a PTC strip of about 1 Ohm per stick, making about 20 Ohms for the Pack at room temperature.

Perhaps this PTC strip is is used by the BCM to select the Pack Fan, anyone know the answer to this?

[Mike Dabrowski 2000]

The PTC strips seem to be an overtemp detection system. Each cell has a PTC sensor, and the sensor will increase resistance quickly when the cell gets in the 160F and higher range.
The other sensors actually are thermistors that allow linear measure the temperature, and they are likely the source of the BCM temp parameter that Peters BCM monitor is displaying.

[JimIsbell]

OKI, so if I dont see a thermistor on the side of the stick, then the replacement one doesnt need one. If I do see a thermistor on the stick then I need to remove it and put it on the replacement stick?

[retepsnikrep]

Originally Posted by E27006

Perhaps this PTC strip is is used by the BCM to select the Pack Fan, anyone know the answer to this?

Not Asfaik. The PTC sticks are the safety of last resort.

The fan activates depending on the temp from the four others sensors. You should soon be able to corelate temp and fan activation point using the gauge.

[JimIsbell]

Are the thremistors attached to the stick directly or are they inside the stick? Can the stick be pulled out of the stack with the junction board (the one with components on it, not the orange one, I differentiate because the orange boards are also connectors) to the left without disconnecting the thermistor, by just disconnecting the PTC Strip and the end bolt. So far in replacing sticks I havent had one that couldnt be taken out that way so I assume that I havent removed one with a thermistor attached....OR....the thermistor is NOT attached...OR....it detaches without much effort when the stick is pulled.

[Hybrid-Battery-Repair]

Originally Posted by JimIsbell

Are the thremistors attached to the stick directly or are they inside the stick? Can the stick be pulled out of the stack with the junction board (the one with components on it, not the orange one, I differentiate because the orange boards are also connectors) to the left without disconnecting the thermistor, by just disconnecting the PTC Strip and the end bolt. So far in replacing sticks I havent had one that couldnt be taken out that way so I assume that I havent removed one with a thermistor attached....OR....the thermistor is NOT attached...OR....it detaches without much effort when the stick is pulled.

They are taped to the stick and another layer of shrink is over them. You have to take them out from the side with the wire or you'll damage them. Just transplant the thermistors to the new sticks with scotch tape.

[JimGnitecki]

I can't believe it: I actually hit the current end of this thread!! It took me a week of part-time reading between other things!

I so SO impressed by the level of technical knowledge here. I'm a degree'd mechanical engineer (Engineering Physics & mechanical Engineering), but not an electrical engineer, so much of this is rapid exposure and shallow education for me.

But, it is obvious to me that this grid charger is a GREAT idea, and that Mike Dabrowski is a very energetic, knowledgeable, and incredibly generous man. There are very few people that would so freely share this much knowledge.

A number of others on this thread are also impressive in their knowledge and generosity in sharing it.

I'd like to go on record thanking each and every one of you, and especially Mike.

I just got my insight, a 2006 with only 62,500 miles on it, two weeks ago, and have been lurking around this site ever since. It's clear that this is THE place to get, and also to give, knowledge and experiences that help each member of the forum.

I'll try to give at least as much as I can. My knowledge is primarily on the mechanical vehicle engineering side. Among other things, I built years ago a computer model that analyzes the effects of power curve changes and gearing changes on any specific vehicle's performance, once the required raw data is entered. I have used it successfully for cars, trucks, motorcycles, and recreational vehicle buses. I modeled the insight in it, and the results were striking in a number of ways. One example is that Insight acceleration is relatively comparatively insensitive to gearing (due to its light weight), but incredibly sensitive to further small weight reductions (due to the low overall (engine plus battery) power available.

I regard my Insight as my newest "science project".

Mike, when you have a price set of the grid charger, let me know. I'll be wanting one. If you've still got that waiting list going, put me on it.

Jim G

(Jim Gnitecki, JimGnitecki@msn.com)

[Mike Dabrowski 2000]

Thanks for the kind words.
I am back on the grid charger project, and hope to be able to capture the parts and labor cost soon, so I can set some prices.
I am still looking for the best bulkhead connector to make the 6 connections that I require for the system.

[Mr. Mik]

Originally Posted by Mike Dabrowski 2000

Thanks for the kind words.
I am back on the grid charger project, and hope to be able to capture the parts and labor cost soon, so I can set some prices.
I am still looking for the best bulkhead connector to make the 6 connections that I require for the system.

I hope you are continuing the grid charger development including the 360V universal hybrid / EV charger version.

If so, could you please include the corresponding connectors to make a wiring harness for other vehicles?