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Proposal: "Grid Charge" for NiMH, "L1 Charge" for Lithium

643 Views 9 Replies 4 Participants Last post by  mudder
I have observed several posters refer to grid charging as a way to balance an LTO pack, and with LiBCM soon to leave beta, it is a matter of time before someone attempts to hook a grid charger to an LiBCM pack for whatever reason. Because of the possible severe outcome of that event, I am proposing that rather than attempt to educate people on the nuances of grid charging, that the term "grid charging" be used only for NiMH charging, and than an industry term such as "L1 charging" or maybe "PHEV charging" be used for lithium, with an emphasis made to "NEVER GRID CHARGE LITHIUM" because of the severe risk posed by lack of automation.

"Grid Charging" is the default cure-all for NiMH battery woes cited on InsightCentral. The term "grid charging" is synonymous with "balancing" for NiMH packs. A "grid charger" is attached to the pack and charges the pack past 100% SOC, which allows lower capacity cells to fill up while full cells burn off the excess charge current as heat. "Hooking up a grid charger" is a specific process where the charger is connected to the pack in specific locations, the pack turned on, and the charger left running for an indeterminate time. All but the most expensive grid chargers provide no automatic shutoff.

For lithium, however, not only will this process NOT balance the cell, it can damage or destroy it and possibly take the car and wherever it is parked with it! This is counterintuitive because most lithium cells in consumer electronic devices have a built-in cutoff switch inside the cell packaging which is difficult to defeat without destroying the cell. However, the LTO packs and the Honda Insight packs used for LiBCM have no such protection. LiBCM provides voltage detection and charger cut-off for its built-in charger.

For completeness, we should explain why L1 PHEV charging differs from grid charging:

GRID CHARGER
NiMH
Lithium
Attempted recovery of problem packsFrequently recommended at InsightCentral, results mixedNEVER!!! Packs with problems require expert care to prevent fires
Balancing an unbalanced packFrequently recommended at Insight Central, results mixedNEVER!!! Lack of automatic shutoff can lead to pack damage and fire!
Refilling a depleted packCan lead to cumulative damage to packNEVER!!! Lack of automatic shutoff can lead to pack damage and fire!

On the other hand, an PHEV charger, defined as a charger that can automatically terminate pack charge when any one cell reaches capacity, but alone does not perform balancing, is pretty much

PHEV CHARGER
NiMH
Lithium
Refilling a depleted packYES - detects pack reaching 100% SOC (or specified voltage) and terminates charge. Used to save fuel. Must be designed specifically for the pack for proper charge termination sensing.YES - primary use is to save fuel. Terminates charge when any cell is found to reach specified SOC (voltage). Must be designed specifically for the pack for proper charge termination sensing and detection of events that may lead to thermal runaway.
Balancing a packNO - Cannot overcharge a pack and therefore cannot balance itNO - Cannot charge cells individually and thus will never balance it
Attempted recovery of problem packNO - A problem pack may never trigger the automated charge disconnect; higher rate chargers may overheat pack or cause a fireNO - Problem packs are a safety risk and require special handling

An Insight owner who, for whatever reason, decides to attach a grid charger to an LiBCM pack or the most common LTO implementation which reuses the NiMH pack switch board will find that the instructions for connecting a grid charger to a NiMH pack will allow it to be connected to lithium pack because the connection points have not changed. But, if they actually flip the switch and charge it as they would like a NiMH pack, they would be in for a very nasty surprise.

This proposal, then is to:
  • Refer to grid charging as applying ONLY to NiMH technology
  • Use the term "PHEV charging" and "PHEV charger" for lithium home charging technologies
    • and that every PHEV Charger must include individual cell voltage sensing AND automatic shutdown when any cell reaches the set point
    • Other safety-related controls are advised (such as thermal sensing, etc)
  • New mantra: "NEVER GRID CHARGE A LITHIUM PACK"
    • Pack voltage monitoring will NOT detect a single overvoltaged cell
    • Inattentiveness may lead to loss of vehicle (or worse)
Using "L1 charging" also lets us speak about an "PHEV charger" which has a VERY important safety feature that a grid charger does NOT have: a means of shutting off the charge current when any cell in the pack reaches capacity. In this respect, one could say that @mudder's LiBCM has a "built-in PHEV charger".
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I certainly agree that overcharging lithium is dangerous. I can also see the benefit in using two different terms for the two different charger topologies:
A) 'dumb' chargers that continuously source current, useful for NiMH cells, but dangerous for lithium.
B) 'smart' chargers that also source current, but turn off when any lithium cell is full.

Obviously these are both 'grid chargers', but given that the insight community has already appropriated that term for 'A', I agree we probably shouldn't use that term for 'B'. However, given how familiar the insight community is with 'A', we will probably never truly prevent the term 'grid charger' from being applied to both 'A' and 'B'.

So yes, I agree choosing a different term makes sense.

I've added a note to update the documentation on linsight.org (e.g. FAQ, installation text, etc).
However, I don't intend to update the installation videos anytime soon (or possibly ever), as that will take way more time than I'm willing to commit at the moment.

Going forward, I will change my messaging from 'grid charger' to whatever term we come up with.

Feedback on your proposed terms:
"PHEV Charger" - The EHW5 modules LiBCM is designed for aren't large enough to call it a 'PHEV'. In addition, a PHEV typically has an "all electric" mode, which isn't possible with the G1 insight's mechanical configuration.
"L1 Charger" - My concern is that customers might expect LiBCM to natively work with CHAdeMO, whereas LiBCM uses a 5-15P connector (i.e. a standard US wall outlet). Most L1 chargers on the market use the CHAdeMO standard... I wouldn't want a customer to think they could purchase these chargers and have them work.

To overcome my feedback on the above terms, I propose the following terms:
"Plug-in Charger" - Simply conveys to the user what the device does.
"Smart Grid Charger" - Allows the lay user to infer that there is also a "dumb grid charger". Further, it preserves the existing "grid charger" usage in-place, while also allowing us to be more specific going forward.
"Lithium Grid Charger" - Same as above, it conveys the idea that there is a separate class of "non-lithium grid chargers".

Of my three proposals, I much prefer the term "Lithium Grid Charger", as it fully conveys this different class of charging devices.

...

As it pertains to LiBCM specifically, the installation instructions and FAQ are VERY clear that only approved chargers should be used with LiBCM. Of course that doesn't prevent a future owner from connecting a grid charger after-the-fact. Note that all LiBCM units ship with a lithium grid charger, so that the user has that support out-of-the-box (and is thus less likely to add an unsupported charger after-the-fact).

Technical note: LiBCM uses the same general charger topology as all extant NiMH chargers (constant current source). However, LiBCM also incorporates redundant control logic to disable the charger as needed for cell safety. Technically you could safely use existing NiMH chargers with LiBCM, AS LONG AS YOU CONNECTED THEM THROUGH LiBCM's control circuitry. THIS IS NOT RECOMMENDED, but is technically possible. There is no benefit to doing this.

One solution to prevent after-the-fact NiMH grid charger installation is to include an additional warning label near the junction board. Proposed text:

WARNING: CONTAINS AFTERMARKET BATTERY.
FOR USE ONLY WITH LITHIUM GRID CHARGERS!

Motor vehicle Bumper Steering wheel Electrical wiring Automotive exterior


Thus, a user who fails to notice the existing "contains aftermarket lithium module" label (included with LiBCM and attached to the IMA bay aluminum cover) will get a second warning as they connect the grid charger to the junction board.
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@mudder Thank you for the feedback.

Good arguments against "PHEV" and "L1" as terms.

My only issue with "Lithium Grid Charger" is that is still has the word "grid" in it.

I do recognize the challenge in removing the reference to "grid charging" from the videos. Perhaps in the video description you could mention the new term that you are using if it's one of those where it is discussed a bit.

I might suggest "Lithium Smart Charger" which replaces "grid" with "smart". This helps further firewall "grid" to the NiMH side while implying that it does important things that a grid charger cannot.

For example:

"Never attach a grid charger to a lithium or LTO pack. Only use a lithium smart charger that is designed for the system" or "LiBCM has a lithium smart charger built into it. Never attach a grid charger to LiBCM"

If I try to use "lithium grid charger" in a sentence I get this: "Never attach a grid charger to a lithium pack, only use a lithium grid charger" which, at least to me, begs the question, "what's the difference" and either requires more 'splaining or degrades into an argument about whether or not the poster is capable of adequately monitoring their kludge.

That, however, is still better than what we have now. The changes you made to your documentation may help someone avoid a regretful mistake in the future.

Have a great weekend!!!!
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This is better discussed separately:

DANGER: FOR USE ONLY WITH LITHIUM GRID CHARGERS!
VEHICLE CONTAINS AFTERMARKET LITHIUM ION BATTERY
What is printed here is ultimately something you'd want to discuss with your lawyers?

Taken alone (as a mechanic or second-hand owner would) the current wording could imply that there is some "lithium grid charger" out there that CAN be safely attached. The user googles "lithium grid charger" - fast forward to a future with this eBay/Amazon listing: "HYBRID BATTERY CHARGER NIMH LITHIUM GRID CHARGER"

In fact one can't make a "lithium smart charger" for LiBCM or LTO without building it specifically for LiBCM or LTO because how will it determine when one cell has reached peak?

Honda simply writes "DANGER - HIGH VOLTAGE - You will be killed or hurt". Note the mention of consequences. How do you say "improper charging of a lithium pack can lead to catastrophic failure that may burn down your car, house, children, start a cane fire, or supply enough energy for the creation of a Higgs Boson and resulting destruction of the universe" as succinctly as Honda does?

"You will be killed or hurt" - yikes
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"Lithium smart charger" is maybe as problematic as "lithium grid charger".

The common hobby smart charger does not need more than a positive and negative connection to a pack. The hobby packs themselves may have overvoltage protection. For lithium, the "lithium smart charger" must monitor individual cell voltages to know when to terminate the charge. Therefore any "lithium grid charger" or "lithium smart charger" must be designed specifically for the installation since cell voltage monitoring will either require extensive tap wiring or obtaining cell voltage information from the pack's MCU.

So any charger for LTO or lithium must be custom designed or the owner risks damaging their pack or worse.

Perhaps it is simply enough to relegate "grid charger" to NiMH land and never use "grid charger" when referring to lithium (at least within InsightCentral because of the history of the term).

@mudder could use the term "Linsight-approved lithium pack charger" or some variant for LiBCM. The rest of us might be stuck with "never grid charge a lithium pack! use a custom-designed charger that reads individual cell voltages and can shut down automatically".
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LiBCM comes bundled with a charger. The likelihood of someone wanting to connect a dumb charger to it, is basically nil.

I'm good with Lithium Grid Charger. It's simple and does what it says on the tin. It also implies a distinct difference between that and a "grid charger."
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For example:
"Never attach a grid charger to a lithium or LTO pack. Only use a lithium smart charger that is designed for the system" or "LiBCM has a lithium smart charger built into it. Never attach a grid charger to LiBCM"
"Never attach an NiMH grid charger to a lithium or LTO pack. Only use a lithium grid charger that is designed for the system"

If I try to use "lithium grid charger" in a sentence I get this: "Never attach a grid charger to a lithium pack, only use a lithium grid charger"...
"Never attach a grid charger designed for NiMH cells to a lithium pack; only use lithium grid chargers approved for use with LiBCM."

...which, at least to me, begs the question, "what's the difference" and either requires more 'splaining or degrades into an argument about whether or not the poster is capable of adequately monitoring their kludge.
There isn't any difference between the actual grid charger hardware, which is just a constant current source (typically an off-the-shelf LED driver). The difference is how the grid charger hardware is connected to the battery:
-In the OEM NiMH configuration, the grid charger hardware is connected directly to the battery, and is allowed to run for a predefined time limit or indefinitely; either method is dangerous for lithium chemistries.
-In the LiBCM configuration, the (same) grid charger hardware is routed through LiBCM, which can then control the output current level (e.g. 400 mA, 125 mA, 0 mA, etc). As an additional safety measure, LiBCM can also electrically disconnect the grid charger's AC line input (e.g. if the grid charger outputs more current than LiBCM commands, if a cell voltage gets too high, or if LiBCM is unable to safely charge for some other reason). LiBCM provides additional safety measures that aren't relevant to this conversation (e.g. double-insulated safety isolation, reverse blocking diodes, no high voltage connections required besides a standard extension cord, audible beeping and flashing alert whenever the cell voltage gets out-of-bounds, etc).

Your concern about customers installing NiMH grid chargers is one of the primary reasons I opted to include a compatible lithium grid charger with every LiBCM purchase. Specifically, I do not offer LiBCM for sale without a lithium grid charger.

...

Taken alone (as a mechanic or second-hand owner would) the current wording could imply that there is some "lithium grid charger" out there that CAN be safely attached. The user googles "lithium grid charger" - fast forward to a future with this eBay/Amazon listing: "HYBRID BATTERY CHARGER NIMH LITHIUM GRID CHARGER". In fact one can't make a "lithium smart charger" for LiBCM or LTO without building it specifically for LiBCM or LTO because
Refer to my technical discussion on the actual hardware above. LiBCM can in fact work with off-the-shelf hardware, just as long as you connect it correctly such that both the grid charger's mains voltage (AC) and HVDC voltage connect to the appropriate screw terminal connectors on the LiBCM PCB. You could connect any commercialized NiMH grid charger through LiBCM and it would work properly... but I don't know why you'd do that, as even the no-cost lithium grid charger that comes with LiBCM will charge the battery faster. In short, there's no reason to pay $1000 for an NiMH grid charger, given that LiBCM's standard one is superior for lithium charging... and given that LiBCM's upgraded grid charger is another 5x faster - and only costs a couple hundred dollars - I'm not sure there's any value proposition for anyone to 'undercut' my rock bottom pricing. But hey it's a free market (and an open source product), so I'd love to see some 'competition'.

how will it determine when one cell has reached peak?
LiBCM does this separately from the grid charger configuration. Even if you install an NiMH grid charger incorrectly (i.e. directly to the lithium battery), LiBCM's beeper would be going crazy as soon as the first cell voltage exceeded the conservatively safe setpoint (4.05 volts or so). The beeper would remain on for at least an hour prior to any actual dangerous condition occurring.

I believe I've taken appropriate safety precautions. Will someone still pull a stupid and do it? Maybe... but to dissuade that event:
-I've included a compatible lithium grid charger for free which is faster than all commercial NiMH solutions, and;
-I offer even faster grid charging options for substantially less than any commercial off-the-shelf NiMH grid charging solution, and;
-discussed the safety concerns of installing a NiMH grid charger at length in the installation videos, and;
-will add the safety label discussed previously (and more below).

Honda simply writes "DANGER - HIGH VOLTAGE - You will be killed or hurt". Note the mention of consequences. How do you say "improper charging of a lithium pack can lead to catastrophic failure that may burn down your car, house, children, start a cane fire, or supply enough energy for the creation of a Higgs Boson and resulting destruction of the universe" as succinctly as Honda does?
The label proposed in this thread is the fifth LiBCM-specific safety label included with each kit:
-"DANGER HIGH VOLTAGE" on the clear cover surrounding LiBCM, and;
-"CONTAINS AFTERMARKET LITHIUM BATTERY. LINSIGHT.ORG FOR SERVICE INSTRUCTIONS", and;
-orange tape around all high voltage cabling, and;
-"WARNING: CONTAINS AFTERMARKET BATTERY. FOR USE ONLY WITH LITHIUM GRID CHARGERS!"
-Numerous "DANGER: HIGH VOLTAGE" labels on the PCB silkscreen.

...

"Lithium smart charger" is maybe as problematic as "lithium grid charger".
The common hobby smart charger does not need more than a positive and negative connection to a pack. The hobby packs themselves may have overvoltage protection. For lithium, the "lithium smart charger" must monitor individual cell voltages to know when to terminate the charge. Therefore any "lithium grid charger" or "lithium smart charger" must be designed specifically for the installation since cell voltage monitoring will either require extensive tap wiring or obtaining cell voltage information from the pack's MCU.
The LiBCM PCB itself is the "smart charger", as it alone controls when charging can occur (and at what current level).

So any charger for LTO or lithium must be custom designed or the owner risks damaging their pack or worse.
I'm using off-the-shelf constant current LED drivers, but routing them through LiBCM, which then controls their output behavior.

Perhaps it is simply enough to relegate "grid charger" to NiMH land and never use "grid charger" when referring to lithium (at least within InsightCentral because of the history of the term).
Putting the ic.net-specific usage history aside, LiBCM is more of a "grid charger", whereas when used with NiMH packs it's more of a "pack restorer". I'm not proposing we retroactively stop using the term "grid charger" for its historical NiMH usage, but rather am just pointing out that LiBCM's configuration better fits the actual purpose served (i.e. storing energy in the pack sourced from the grid).

I agree that generically using "grid charger" could set customers up for failure. To that end, changing the messaging to "lithium grid charger" conveys that only certain grid chargers will work. And if that fails, there's always the potentially problematic "FOR USE ONLY WITH LITHIUM GRID CHARGERS" warning label placed right where the customer would connect one.
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This all seems good. The only thing I might add is that the idea that someone may parallel a charger with LiBCM is not too far-fetched. I thought I was about to see the first instance of this today while I was reading the excellent post about the J1772 connector being put though the bumper. I kept thinking, he's connecting to a charging station so he must have paralleled in a high current charger so he doesn't have to sit there for hours! ...and was expecting a write up on this wondering if and how he was reading cell voltages.

It looks like the answer is "no", he is just using it as an AC power connector for LiBCM's lithium grid charger.

But I've seen enough half-baked ideas on the interwebs that I can imagine someone paralleling a high current high voltage supply found cheap on eBay with a pack without adding cell-level voltage sensing. So the warning stickers against doing this are probably a good idea.

Have a great weekend.
x
Never attach a grid charger designed for NiMH cells to a lithium pack; only use lithium grid chargers approved for use with LiBCM.[unquote]

Actually, I've had good luck so far using a programmable Genesis charger to charge my LTO pack. I just program in my stop voltage, and the charger charges until it gets there. True of course that the charger gets no feedback from the battery so there are some safety issues, but the method has proven reliable for 3 years now.

The Genesis charges at only 1A and has a programmable cutback to 350ma, so it seems relatively safe. Of course a failure of the Genesis controls would be a disaster:eek:
This all seems good. The only thing I might add is that the idea that someone may parallel a charger with LiBCM is not too far-fetched. I thought I was about to see the first instance of this today while I was reading the excellent post about the J1772 connector being put though the bumper. I kept thinking, he's connecting to a charging station so he must have paralleled in a high current charger so he doesn't have to sit there for hours! ...and was expecting a write up on this wondering if and how he was reading cell voltages.

It looks like the answer is "no", he is just using it as an AC power connector for LiBCM's lithium grid charger.
Yeah there are at least two LiBCM owners who have installed this mod... you are correct: it just plugs into LiBCM's lithium grid charger's 5-15P plug.

But I've seen enough half-baked ideas on the interwebs that I can imagine someone paralleling a high current high voltage supply found cheap on eBay with a pack without adding cell-level voltage sensing.
When I need to charge my pack quickly, I do precisely this:
-First I plug in LiBCM's stock grid charger. This turns on the 4x20 display so I can monitor SoC and cell voltages.
-Next I connect a high current wall-mounted fast charger in parallel (using an Anderson connector). This can charge the pack from empty to full in 20 minutes.
-I NEVER leave the garage while charging, as I need to manually disable the external charger once the pack is full. I usually just make LiBCM-related parts/cables or whatever.
-In the event I lose track of time, LiBCM will enable the buzzer when the first cell reaches 4.05 volts.

Eventually I will connect LiBCM to the wall-mounted power supply via a dedicated serial bus... but that won't be anytime soon. That will dramatically increase safety. At that point I'll document and share the hardware setup.
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