Plug-In Supply DIY

Banshee. I'm working on a complete replacement. Recreating the approach pEEf took. However personal circumstances has caused a big delay & I'm not sure when I'll finish. I'm confident I have enough understanding - but its a question of time.

I plan on open sourcing the results.

DROID RAZR ? 2

 

jdh2550,

Been tracking you work, very appreciative of the effort you are putting forward. I noticed the Gen2 are getting lots of attention and that is great. I wish I had the know how to do what you are doing with the Gen2 on the Gen3. Not many options for the Gen3 at this point. I have been running a 8 kwh Enginer system since 2010 and have about another 3 years left before I hit 200,000 miles. I figure by then I would replace the OEM HV battery completely.

 

A second hand PIS kit is for sale at this thread:
EV Kit Plugin Supply 10KW - used | PriusChat
I just thought that subscribers to this thread might be interested. It appears to include a ECM spoof PCB which allows highway speed in EV mode.

 

Please remember while it is technically possible to go "highway speed" in EV mode it is hardly practical in a gen2 Prius. You only have about 30 horsepower getting to the wheels no matter how big a battery and no matter what software you add to the car (inverter and motors inside the transaxle are the limitation.) Acceleration after 35mph is dreadfully slow and can be unsafe. It will also drain the battery very quickly at high speed. However, EV mode is great for "around town" neighborhood trips. If you want to go highway speed without gas, buy a Leaf, Volt, Tesla etc which has a big enough electric drive system for the task.

 

3prongpaul is right - pure EV is good for driving in the small streets ony. Using a little gas is not a big deal. The safety is the big deal. Even 2012 Plug-in Prius does not allow pure EV driving in any case as the spoof board do.

 

PIS supply for sale.. make offer. 3 years old. Reason.- works great when all cells balanced but temperatures here in SW Florida are so intense, if the car is not garaged (as mine is not) cells overheat and have to be replaced. I have 4 more new ones arriving next Tuesday. I can't afford to keep doing this so need to sell to someone in a cooler climate or someone who can garage the vehicle during the hottest part of the day. Internal temps can reach 140+degrees inside my Prius.
Pat. wa4eqw

 

[email protected]

 

This is my first post on this particular thread.
I have now read all previous 21 pages! and think it's time to put my bit in.

I have purchased and received all of the major components (except batteries, BMS and charger) from Plug-in Supply (PIS).
My experience to do with Robb from PIS is that I find him to be a very knowledgeable and sincere person.
Yes, as a very busy guy, he does seem to make promises of delivery which he has trouble meeting, but the goods come through. He is very easy to talk to (on Skype) and has all the answers to my questions.
The kit that I received is the "10KW" one to work with 76 Winston LYP40AHA 40Ah cells (Y = Yitrium).
I will be using the EV-Power BMS modules (Australian) and a TC Charger (Elcon) charger setup for Lithium ion cells with 2 wire enable which connects to the rear PIS controller.

My blog will continue be updated as I progress (very slowly with other work taking preference).
www.evplus.com.au

I have done the front wiring - easy in Australia, because we already have an EV button istalled from the factory.
I have connected to the main pack ready to connect to the PIS Contactor box.
I have started making the steel frame to house the 76 cells.
I have also received the cells, charger and BMS modules.

BTW - I have met Steve and his wife from AutoBeYours at the (Annual)2012 EVCCON (by Jack Rickard - EVTV) in Missouri (my first and probably only trip to the US).
Steve is a great guy and as someone else said, he probably is the most knowledgeable when it comes to the Prius.

Eric (South Australia)

 

Welcome Eric.. Yes Robb the designer of the system and owner of P-I-S and Steve and Jenny of autobeyours.com and Dimitri of Clean Power Auto (the BMS designer) are great folks and I have been extremely happy with their support.
Sadly, the GBS-LFMP40Ah cells that I'm using don't like the interior temperature in the car parked outside. When the next 4 new cells arrive on Tuesday, that will be 12 that I've had to replace in the last 3 years. I'm cutting my losses when it's back working properly and selling it.
Good luck Eric
Pat. wa4eqw.

 

Of course, If anyone wants to buy my 2006 GenII Prius before I take the pack out, you can have it for $10,500 complete (102,000 miles). I will just buy another insurance rebuild from Steve.. but without PHEV.
Pat. wa4eqw
willtravelus@gmai

 

that is [email protected]

 

You did not stipulate that "please " The Gen 2 may follow under your suggestion however,Gen3 has different specs and has a ev mode configured.
Nissan Leaf and Tesla S are more interstate (high speed) do able.....But Gen 3 Plug in can do higher speeds than 35mph

 

FYI
Battery physical weight, energy density, charging, and discharging have been ev hurdles and obstacles that are always part of the feasibility of EV performance...............

 

Just a quick report that my Plug-In Supply 10kWh plug-in conversion is now completed and working extremely well.
It is winter here and the heater and demister are on for most of the time which causes the engine to run very often.

I am happy to report that even with the heater running, we are using an average of only 2.8L / 100km of petrol. (101mpg (imp))
In fact our petrol gauge is just under half and we have driven over 1000km so far, on this tank.
I am predicting that this will reduce to around 2.2L / 100km (about 130mpg (imp)) by summer time (i will report back then).

This driving includes lots of hill climbing and high speed driving (up to 100Km/h)

The Plug-In Supply system uses 32Ah from the 40Ah battery before the system switches off.
This leaves 20% SOC in the additional pack, which is exactly what I wanted, so no additional circuitry is required to achieve this outcome.
This is being monitored by a JLD 404 meter which I highly recommend. (Volts, Amps [Charge and discharge], Ampere Hours [Charge and discharge], and Time). I use a 12V / 12V DC Isolator with this.

I continue to update my "Blog" on my website (EVPlus - Electric Vehicles & Hybrids), but this is a little snippet which is not there yet.

Eric

 

Hi
I'm selling my PiS parts for gen 2 and 3.
See this thread if you're interested.
For Sale - Plugin supply kit for gen 2 and 3 | PriusChat

 

Hi again,

I have now updated my blog with the details of the "ICE Kill Switch" wiring.
Please check it out: EVPlus - Electric Vehicles & Hybrids
btw: 2.7L/100km average at the moment.

I am sorry that my blog is not up to date. The modification is now complete and I still have to describe the "Rear Controller" and "Rear Contactor" wiring etc.
I am very happy with the way everything is working.

Eric

 

UPDATE - NOVEMBER 2015

We are now getting an overall average (over 1000's of Km) of 2.4L/100km.
By charging each night we are getting over 1000Kms to half a tank of petrol.

Check the Blog section...

Eric.
EVPlus

 

That is one cool do it yourself project from down under - what kind of thermal management does it have?
.

 

Thanks,
I have three 240V fans on the charger. (this was necessary because of the horizontal orientation of the heatsink fins. To fit the charger where I wanted it, it had to be this way. Notice the charger is right out of the way. I didn't want it taking up space in the boot (trunk) and I didn't want it on the rear passenger floor!
The battery section uses convection cooling with vents under the battery frame and the cells have built in grooves between them to allow air movement past them.
The polycarbonate cover over the cells is only slightly warm after a full charge. This warmth is probably from the (EV Power) BMS cell modules that bypass the cells at the end of charge.
These BMS modules are basically the same ones that I used on my EV conversion (EVric)which I have been driving electric now for over 5 years, without a problem - highly recommended. They are a simple analog device.
The charger is basically set to a maximum voltage of 3.65V per cell (76 cells) which is when the BMS cell modules start to bypass.
Eric