PHEV mod under way, Bristol, UK.

[mrbigh]

Originally Posted by aminorjourney

Yes!

What year module was it which went wrong for you? Had it been involved in any nasty incidents like mine?

Of course, when I build the next pack fans will be employed to keep everything hunky-dory!

We also have to remember that those of us who are doing this particular method of conversion are in fact a little bit of a cheap-skate. We are using second-hand packs!!!



Nikki.

The failed pack came from an early 2007 and blown in 2008, and on his one, I haven't checked the integrity of the modules, because I underestimated the age and the full frontal collision the vehicle went through.
All other packs I made, for my personal use and resold, I had check module by module under charge and discharge and plotted their conditions, discarting the weaker o border line ones.
-Cheap-skate?!!! I'm sorry....By buying a new add-on pack, we are expecting to shell-out u$s3600.00 for each one, sorry but I have to keep eating during the year thou. I'm using recertified modules at much lower cost.
Best regards
Horacio

[aminorjourney]

Originally Posted by mrbigh

The failed pack came from an early 2007 and blown in 2008, and on his one, I haven't checked the integrity of the modules, because I underestimated the age and the full frontal collision the vehicle went through.
All other packs I made, for my personal use and resold, I had check module by module under charge and discharge and plotted their conditions, discarting the weaker o border line ones.
-Cheap-skate?!!! I'm sorry....By buying a new add-on pack, we are expecting to shell-out u$s3600.00 for each one, sorry but I have to keep eating during the year thou. I'm using re certified modules at much lower cost.
Best regards
Horacio

Interesting. I wonder if I should do what you have done when building the packs this time. Battery Number 3 (the replacement) arrives today...

Nikki

[Flying White Dutchman]

thats fast

damm i want to get a pack on short notice like that.

currently the dealers i talk to dont want to sell there packs because toyota is contacting them to get the packs from them for resycling.

not sure anyone else also got this info?

[Flying White Dutchman]

Originally Posted by aminorjourney

My cables are 6AWG - so bigger than the EAA-PHEV wiki requires. What size are you using?

Nikki.

ok i got a look and its 16mm cabling so i guess 16AWG ( edit: looking at the link i think where the same size so i also have 6AWG )

RED color

edit :

AWG American Wire Gauge to mm2
http://www.palonn.com/sommer_cable/awg_mm.htm

[aminorjourney]

Originally Posted by Flying White Dutchman

ok i got a look and its 16mm cabling so i guess 16AWG ( edit: looking at the link i think where the same size so i also have 6AWG )

RED color

edit :

AWG American Wire Gauge to mm2
AWG to mm2

Yup - That's right.

I have 16mm / 6AWG too. The minimum recommended is 8AWG, so we're both one size larger than is recommended.

The new battery has arrived and the old one is now at the Tip. Hopefully there will be some more photos soon....

N

[Mjolinor]

Originally Posted by aminorjourney

Yup - That's right.

I have 16mm / 6AWG too. The minimum recommended is 8AWG, so we're both one size larger than is recommended.

The new battery has arrived and the old one is now at the Tip. Hopefully there will be some more photos soon....

N

You dumped the old battery?
Seems a bit rash to me

[aminorjourney]

Originally Posted by Mjolinor

You dumped the old battery?
Seems a bit rash to me

Not if you've seen the old battery! The local Tip actually take the batteries for recycling, so it won't go into landfill.


Obviously, I made it safe before I took it there and disconnected the links between cells.

I'll try and get a photograph of some of the corrosion too at some point.

[Mjolinor]

Statement withdrawn

I thought Toyota would buy them back?

[Flying White Dutchman]

oo jesus

this just because one cell failed? and made a shotcut?

did you ever check the corrosion on the other packs?

there still is one thing i dont have and you do.. this is that i have not yet connected the packs with the andersons connector
i have a straight connection between te pack with large connectors.

maybe you can do a drive with just 1 pack connected and see what the internal Ohm ristance is from canview.. i will do the same and compare this.
every connector wil have a little add to the risistance level.


i got corrision or what you wanna call it to on my addpack.

http://priuschat.com/forums/care-mai...corrosion.html



]

[aminorjourney]

Originally Posted by Flying White Dutchman

oo jesus

this just because one cell failed? and made a shotcut?

did you ever check the corrosion on the other packs?

there still is one thing i dont have and you do.. this is that i have not yet connected the packs with the andersons connector
i have a straight connection between te pack with large connectors.

maybe you can do a drive with just 1 pack connected and see what the internal Ohm ristance is from canview.. i will do the same and compare this.
every connector wil have a little add to the risistance level.


i got corrision or what you wanna call it to on my addpack.

http://priuschat.com/forums/care-mai...corrosion.html



]

My initial inspection and theory was that some water damage had internally caused a short in two out of the twenty-eight modules. Of course, I also found really heavy corrosion under the bus bars. I shall be cleaning each connection carefully when I build the two new packs...

The corrosion on mine was very greenish in colour. Sadly I've now passed the battery on for recycling as I didn't have room in the garage for it plus the new one I've just picked up.

I'd check your battery voltages for each module and take it from there. Also clean up each connector. Perhaps some emery paper?

I'd argue that the Anderson connector is a MUST. You can quickly and safely remove additional packs completely from the circuit. It's how I managed to get the batteries removed so quickly (five minutes, and then I was able to drive off in regular mode!)

Nikki.



Nikki.