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The Enginer charger is killing the battery pack!

Discussion in 'Prius PHEV Plug-In Modifications' started by hkgngplugin, Nov 8, 2013.

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  1. hkgngplugin

    hkgngplugin Junior Member

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    Guys, I installed the Enginer PHEV a year ago. I have the version 6 arrangement (or the newest version). I already have a pack died for only 6 months. Now I DIY a new pack on myself and found that cell #4 & cell #12 dies very easily. I figured out those two cells are on the bottom and are closest to the charger. Now I have replaced the two cells and moved the charger away from the pack. I think the charger is “cooking” the pack to quite a high temperature. I have measured the ambient air temp for the spare tyre compartment could rise over 40oC. That means the temperature of the pack is even higher! I remember RFE or A123 do not recommend working temperature higher than 40oC.
     
    #1 hkgngplugin, Nov 8, 2013
  2. mrbigh

    mrbigh Prius Absolutum Dominium

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    THOSE BATTERIES MAY BURST IN FLAMES, please disregard use of Enginer until further investigation is made and corrective measures are in place
     
    #2 mrbigh, Nov 8, 2013
  3. dan2l

    dan2l 2014 Prius v wagon

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    Moving the charger will help but will not solve the problem. All LiFePo4 cells generate heat during charging and so the wheel well will still get hot.

    I have never heard of any Enginer system doing the "Burst into flames". I do not think you have a safety problem.

    However, I also have never heard of anyone using an Enginer system past about 3 years. You will find that you will have repeated cells die, even with the charger moved to a different location.

    Thanks,
    Dan
     
    #3 dan2l, Nov 8, 2013
    dave77 likes this.
  4. hkgngplugin

    hkgngplugin Junior Member

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    Dear mrbigh,

    I’m now using A123 cells for the system, and I think burst in flame are seldom, or even rare to happen. I’ve got couple of them “puffed”, or being “blown up,” but none of them bursted or caught in fire.

    Tat.
     
    #4 hkgngplugin, Nov 8, 2013
  5. mrbigh

    mrbigh Prius Absolutum Dominium

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    By the OP first post " I think the charger is “cooking” the pack to quite a high temperature.
    I have measured the ambient air temp for the spare tyre compartment could rise over 400C ".

    Somewhere must be a mistake then......:eek:

     
    #5 mrbigh, Nov 8, 2013
  6. hkgngplugin

    hkgngplugin Junior Member

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    Dear Dan,

    Moving the charger away helps alot. The ambient temp in the wheel well is now 8-10oC cooler. The charger was originally attached to the U-shaped stainless steel containing the battery pack. It got very,very hot every time I charged the pack. By only moving the goddamn charger away, the stainless steel container is now cool when charging.
    Now I am planning to move the charger outside the car to minimize the bad effect of heat generated by the charger to the battery pack.

    Tat.
     
    #6 hkgngplugin, Nov 8, 2013
  7. hkgngplugin

    hkgngplugin Junior Member

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    Oh, that should be 40 degree C, not 400 degree C. My car would have melted down with 400 degree C.
     
    #7 hkgngplugin, Nov 8, 2013
  8. pjc

    pjc Member

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    Dan, what is the most problematic part: the charger or the BMS?
     
    #8 pjc, Nov 8, 2013
  9. HaroldW

    HaroldW Active Member

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    Why don't you cool it with the fan that is used in the car. ;)H
     
    #9 HaroldW, Nov 8, 2013
  10. hkgngplugin

    hkgngplugin Junior Member

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    Dear Harold,

    Your idea is great but I will first move the charger outside the car and see how it would do before adding fans to the battery pack. One less heat generator means a lot cooler!

    Tat.
     
    #10 hkgngplugin, Nov 8, 2013
  11. hkgngplugin

    hkgngplugin Junior Member

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    Guys, I have moved the charger outside the car today. It’s really alot cooler without it inside the car. Now, I got only about 28 degree C at the wheel well during charging.
     
    #11 hkgngplugin, Nov 11, 2013
  12. HaroldW

    HaroldW Active Member

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    While you are charging the pack can you not hot wire the fan that normally cools the pack to run while charging. H
     
    #12 HaroldW, Nov 11, 2013
  13. hkgngplugin

    hkgngplugin Junior Member

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    Dear Harold,

    There are no fans for cooling the battery pack in version 6.

    T.
     
    #13 hkgngplugin, Nov 12, 2013
  14. HaroldW

    HaroldW Active Member

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    Tat, what is a version 6?. :( h
     
    #14 HaroldW, Nov 12, 2013
  15. NortTexSalv04Prius

    NortTexSalv04Prius Active Member

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    You may want to do so thread reading and EV reading about the LifePO4 as well as Enginer past owners post. FYI the following are real world facts concerning BMS (most are based on a top balance approach to charge state) BMS are complicated and do not always work correctly or not installed and used correctly. Even with that said the Enginer BMS is poor quality and could possibly destroy your LifePo4 cells due to top balance and basic overcharge of cells........
     
    #15 NortTexSalv04Prius, Nov 13, 2013
  16. NortTexSalv04Prius

    NortTexSalv04Prius Active Member

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    The cells have a charge range which going over 3.5 vdc really adds little to no extra capacity but , could potentially destroy the cell in the pack...........
     
    #16 NortTexSalv04Prius, Nov 13, 2013
  17. hkgngplugin

    hkgngplugin Junior Member

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    Harold, as far as I know version 6 is a new arrangement of all Enginer components inside the Wheel Well.
     
    #17 hkgngplugin, Nov 14, 2013
  18. hkgngplugin

    hkgngplugin Junior Member

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    I have been looking closely to the cell voltages when in different operations. I found the BMS cut off charging/discharging at HVC 3.85V and LVC 2.5V respectively.
     
    #18 hkgngplugin, Nov 14, 2013
  19. glyndwr

    glyndwr Member

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    as an old enginer version 5 owner, i would strongly advise you take measures to reduce the high voltage cut off point.
    3.85v cut off will reduce the life of your cells over time.
    Think about an alternative bms or a cell log device set up that i used with a hv cut off set to 3.5v. This did work very well.
    Also, the new version bms supplied by pluginhybrid.de does work well and as far as i am aware cuts off the hv at 3.5v. I have seen it in operation and does what is says. It is a vastly improved bms over the enginer bms.
    Whichever route you choose is up to you, but in my opinion you should choose something or damage will occur.

    Anthony.

     
    #19 glyndwr, Nov 14, 2013
  20. Greg Wilson

    Greg Wilson Junior Member

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    Do u have any idea on where to get new cells?
     
    #20 Greg Wilson, Sep 8, 2015
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