Adding Enginer PHEV system.

[ericbecky]

Hi guys,
Well, I've decided to put in an Enginer PHEV system into my Insight.
(See Enginer | Prius Plugin PHEV Conversion Kit with Lithium-Ion | Hybrid for info on their Prius system.)

About my Insight.
- 2002
- 5 speed
- 120,000 miles.
- MIMA system with two joysticks (This is the second gen MIMA system with the pull pin, insert tap system)

I plan on adding 2KWH of Lithium batteries (LiFePO4)

Looking at others PHEV systems it would appear that I will most likely need to remove my spare in order to have room to install the batteries and keep them "below deck".

I installed MIMA myself and I'll be doing this install myself as well.
I have helped with 5 other Enginer installs in Prius, but this will be the first in an Insight.

Since the Insight has a bit less room below deck than a Prius I will probably need to move some components around. My initial idea is to put the battery under the storage pocket, mount the converter in the storage bin and the charger on the side space. I am interested in creating a battery box too.

Once I have the components I can start trying out some placement ideas.

I read through the entire thread about retepsnikrep's PHEV system and mine will not be nearly as powerful or complex.
For example, I don't think I'll need to open the OEM battery module.

At first blush it seems like I may be able to connect via the output terminals of the OEM battery module.

I look forward to hearing other's input and any other links to threads here on IC you think are pertinent regarding this PHEV conversion.


* * * * * *
Other details about the kit (basics taken from Dan Kroushl's summary on PriusChat.)

8/25 edited. This set up is not exactly the same as what is being used in the Prius setup. I edited the specs to identify the voltage that will be used for the Insight setup. Also identified that the output for the converter may be adjustable from the factory.

Thundersky Battery Charger Model 48-15
Input Voltage 99-121VAC, 47-63Hz / Output 58.2VDC @ 15A
Efficiency = 70-93%
Dimensions = xxxx
Weight = xxxx

DC/DC Converter
48-160V 3000W, Output may be adjustable
Efficiency = To be determined
Dimensions 18.75 x 6.88 x 2.75
Weight = 13.0 lb

Cell Balancers
Chargery DB8 Smart Digital Balancer
- Battery Types: LiPo and LiFe cells
- Cells Monitoring : up to 8
- Displays cell voltage, pack voltage and voltage differential
- Current drain for balancing: 300mA/cell.
- Balance accuracy: <10mv
- Over Charge Protection : 4.22V/cell (LiPo), 3.75V/cell(LiFe)
- Low voltage alarm: 3.00V/cell (LiPo), 2.80V/cell(LiFe)
- Voltage display resolution: 0.001V
- Voltage Detection precision: 0.005V
- Dimensions: 4.52” x 2.67” x 0.59”
- Weight:150g
When connected to a set of 8 batteries, the DB8 will lower the voltage of seven cells to the level of the lowest (eighth) cell. It will perform balancing while charging, idle and discharging. It can discharge 7.2Ah per cell per day. Two DB8's are required for a 2kWh kit.

[retepsnikrep]

Good luck with your conversion. Please keep us fully updated with progress. Lot's of potential issues have you got any brilliant ideas you can pass on?

Mine is fully usable and works very well but it's still not finished as I have ben distracted with my BMS remote display away from the BCM anaylsis at the moment. I still need to develop my fake BCM module. That's this winters project.

[IamIan]

Originally Posted by retepsnikrep

PS your link to the site does not work.

she just put an extra 'www'

----------

good stuff... keep us posted.



Things you may want to keep in mind.

#1>
If you are tapping where I think you are tapping... be careful about when you provide current... Mike D ran into an error code that can happen at times if the BCM checks for a no current condition and your 2kW pack is charging the OEM pack at that same second... I think the easy fix was to just provide current only when using Regen or Assist ... and I think Mike found a delay that might have some potential ... but I don't recall all the details.

#2>
I think Peter had said if he used smaller like ~30Ah or ~20 Ah LiFePO4 cells he might have been able to fit it in the OEM space instead of using the spare tire area... but that does require all the rest of the stuff he is still working on as well.

[ericbecky]

Originally Posted by retepsnikrep

Good luck with your conversion. Please keep us fully updated with progress. Lot's of potential issues have you got any brilliant ideas you can pass on?

Brilliant ideas? Don't count on me for those. I was hoping YOU'D have the brilliant ideas.
My main goal is to "not let out the magic smoke" as Mike D once warned me about.

And, hey, thanks for fixing my link.

[Hybrid-Battery-Repair]

Originally Posted by ericbecky

Hi guys,
Well, I've decided to put in an Enginer PHEV system into my Insight.

I plan on adding 2KWH of Lithium batteries (LiFePO4)

Looking at others PHEV systems it would appear that I will most likely need to remove my spare in order to have room to install the batteries and keep them "below deck".

Eric,

Contact me privately. I have a forthcoming product that you will want to hear about.

[retepsnikrep]

Originally Posted by Hybrid-Battery-Repair

Eric,

Contact me privately. I have a forthcoming product that you will want to hear about.

Come on Ron you can't put that on the forum and then not expect us all to want to know what it is?
You could have PM'd him if it was secret!!

[Hybrid-Battery-Repair]

Originally Posted by retepsnikrep

Come on Ron you can't put that on the forum and then not expect us all to want to know what it is?
You could have PM'd him if it was secret!!

To tease you, of course.

Let's just say that 6KW of NiMH batteries only weighs 400 lbs and doesn't require a LiPo charger. That is a direct comparison to A123's PHEV Prius pack that weighs 200 lbs and costs $10,000 as a kit.

2KW weighs only about 130 lbs.

I think that's enough clues for now.

[MN Driver]

Well Ron, I must say you've got me excited to hear about it!

[retepsnikrep]

Originally Posted by Hybrid-Battery-Repair

Let's just say that 6KW of NiMH batteries only weighs 400 lbs and doesn't require a LiPo charger.

I think 400lbs in the back also means bent rear trailing arms if I remember Mike's experience correctly!!

My 40ah pack weighs about 175lbs.

[MN Driver]

Originally Posted by Hybrid-Battery-Repair

To tease you, of course.

Let's just say that 6KW of NiMH batteries only weighs 400 lbs and doesn't require a LiPo charger.

Why do I feel the sudden urge to make a trip to the yards before the price of packs suddenly go up?