Custom Enginer PHEV (8kWh)

[krousdb]

Originally posted on 7/29/09 at PC

I've started this thread for those who want to customize the Enginer.us PHEV kits for longer range and higher performance. I have started with two of the Enginer 4kwh kits. Depending on the way my custom configuration performs, I might add more converter(s) for higher speed EV and/or more batteries for longer range.

I have just finished mounting all of the components. I have not yet run the wires to the dash and mounted the switches. I just used a 12v battery and some jumper wires to provide power to the switches. Everything works fine except that one of my two battery chargers has an internal short that took out a circuit breaker in my load center. Amazingly, the fuse in the charger didn't blow.

I started up the car and engaged Ev mode. The OEM pack SoC was 58.0, voltage at 216, BTA at 1.4A. When I switch on the first converter, the BTA reversed to -7.5, meaning that the converter was putting out about 9A. Then I switched on the second converter. The BTA jumped to -15.5A, or 17A total. Not the 24A that I had expected but the battery voltage was at 240 and the SoC was above 60%. I expect that under load or if I charged the OEM pack when it was vary low, say 200V, then I would see 24A. I will try that soon to confirm.

I let both converters run until the SoC rose to 75% then shut one down. The shut the other one down at 77.5%. No component malfunctions (other than the charger) and no MIL or DTC's.

[krousdb]

Here are the pictures of the component perparation, installation and test drive.....

Preparation

Prepping the chargers


Mounting the 48V to 240V Converters


Reinforcing the battery carrier cover


Increasing the depth of the box (to accommodate batteries standing up)


Battery carrier with cover. 1" clearance over battery terminals.


Battery carrier with cover (rear view)


Installing the Chargers


Battery Carrier Installed


Batteries Installed


Switch Controls Installed (HSS 52MPH, red button)


Installation Complete (rear)


Installation Complete (front)


Test Drive

66 mile trip, similar to one way of my daily commute. 50 miles at 55 mph on the interstate, 16 miles of 35-45 mph suburban driving. 66 miles total.


SG shows 106 MPG. SoC finished the same as where it started at 77%.


Started the 66 mile drive at 53.7V. End of drive was 51.3V. Under load with 2 converters, 50.0V. Converters shut down at 46V. Lots of juice left.



After adding 300 lbs to the rear, the sag is not so bad.

Needless to say, I'm a happy camper.

No component failures (except for one charger), no balancers beeping, no MIL's and no DTC's. The converters were putting out about 9A each, no overheating. I started up with 53.7V on the Aux pack. After switching one converter on, 52.1V. After switching on the second converter, 51.7V where it stayed until about the 50 mile mark. At 66 miles, just before switching the converters off, 50.0V.

So what was the improvement with the Custom Enginer 8kwh PHEV? As I stated earlier, this test drive was very similar to my daily commute one way. Normally on that one way commute, I get 65 MPG. So 106/65= 163 or 63% improvement. This is twice what I had expected. I will report back after tomorrow's commute.

[msantos]

Awesome setup !!!

... and pretty encouraging results, which will only increase the drool factor many of us will be experiencing.

I particularly like the red ejector button !!!

Cheers;

MSantos

[bestmapman]

Can't wait to see your set up in person.

[diamondlarry]

Originally Posted by msantos

Awesome setup !!!

... and pretty encouraging results, which will only increase the drool factor many of us will be experiencing.

I particularly like the red ejector button !!!

Cheers;

MSantos

I like the ejector button. I was thinking of something along the lines of a laser to eliminate tailgaters.

[hobbit]

And it's all in parallel, huh? That's really interesting. You
might want to take clamp-on to various interconnects and check
for stray cross-pack currents under various conditions.
.
_H*

[krousdb]

Today, on the way back from the beach, I picked up my car and drove it home. I used up what was left in my Aux pack and only got 70 MPG on the way home. The 15 MPH headwind and heavy rain didn't help much. That bought my tank down to 90.2 MPG at 640 miles or so.



I decided to install the second charger which arrived on Friday. Everything had to come apart because I have the chargers under the battery carrier. Before removing the batteries, I cyced through all of the cell voltages. I knew that I had 3 weak cells because earlier in the week, I saw them down at 2.4-2.5V before charging. Today they were 1.3, 1.5 and 1.7V. Just my luck, each was in a different pack. So I spent most of this evening replacing the bad cells with some spares that Jack sent me. Then I tested the new charger. Now I am letting the cells balance in the rebuilt packs before putting them on charge. So tomorrow, and possibly the rest of the week, I will be non-PHEV.

[krousdb]

9/09/09 Morning Commute

One Converter only!

Driving Conditions
Dry roads.
Ambient Temp = 64F
Winds = 4 MPH tail wind
Windows Closed
Fan set to level 1, no AC.

Route
12.0 Miles suburban at 25-45 MPH
52.0 Miles in the Interstate, CC set to 55MPH
3.6 Miles suburban at 45 MPH

Results
Trip ScanGauge MPG = 80.6
Current Tank = 61.6 Miles
Tank ScanGauge MPG = 82.0
Tank MFD MPG = 81.8


Analysis
Very similar to yesterday's morning commute with no PHEV, 65.5 MPG

PHEV Performance
80.6/65.5 = 23.0% Improvement using one converter only.

[krousdb]

Filled up on Wednesday. Added new PHEV vehicle and first tank info.

[krousdb]

Finally had some quality time for PHEVing today. I went on two errand runs. The first 28 mile run, speeds 25-50 MPH yielded 128 MPG. The second, a repeat of the first (what I bought was defective) but more under 40 MPH time due to less traffic yielded 168MPG!

Total for the day, 56 miles at 148 MPG. The last 14 mile segment, from the store back home, was 205 MPG.

The last time I did that I was somewhere in the middle of Oklahoma sweating my a$$ off.