Can I bypass the battery cooling fan by forcing air through the intake vent?

Discussion in 'Gen 3 Prius Main Forum' started by KiwiRyan, Feb 25, 2021.

  1. KiwiRyan

    KiwiRyan New Member

    Joined:
    Feb 25, 2021
    1
    0
    0
    Location:
    New Zealand
    Vehicle:
    2010 Prius
    Model:
    N/A
    I got my hand on the Prolong charger and discharger for battery balancing and reconditioning. Trouble is the cable doesn't match my model ( its gen 2 n I'm gen 3)
    I figure I can connect the positive and negative to the battery terminals easy enough but that leaves the cooling issue as the fan connections are incompatible. I'm not keen on wiring a alternate 12-volt source direct to the fan. It's for pins and I don't know which is it which. I'm thinking I can force their down the intake vent during the reconditioning process. But how much is enough. I realise the fan itself will interrupt the flow of air somewhat but the charging is only at an amp dropping down to 350 milliamps so I'm guessing the buildup of heat will be minimal anyway. Still need a constant flow of air to remove any heat.
    Does anybody know the volume of the air the battery cooling fan is rated to?
    I'm thinking 150 cfm should do the trick.
    Any thoughts?
    Cheers
     
  2. PriusCamper

    PriusCamper Senior Member

    Joined:
    Mar 3, 2012
    6,536
    2,752
    0
    Location:
    Pacific Northwest, USA
    Vehicle:
    2007 Prius
    Model:
    Two
    If you were in a place where Gen2 were more abundant I'd suggest going to a wrecking yard and buying a hybrid fan from wreck. I got one for $25US last Fall, which makes charging packs outside of the car possible.

    Alternatively you can find a high velocity 12v fan for the lowest amount of money if you search for electric radiator cooling fan for cars. Then get cardboard and duct tape and make your plumbing.

    Most important, don't skimp on cooling... The more of it the better!
     
    vvillovv likes this.
  3. vvillovv

    vvillovv Senior Member

    Joined:
    Mar 19, 2013
    2,003
    725
    0
    Location:
    NY
    Vehicle:
    2017 Prius Prime
    Model:
    Prime Plus
    besides what PriusCamper posted above, as the pack is being slowly charged some cells reach full charge while other cells are not fully charged yet. The fully charged cells than give off heat for the entire time the other cells are continuing to charge. Good air flow through the pack is needed to handle that heat. ESPECIALLY if a pack is out of balance, which is the reason we all grid charge in the first place. Getting hot spots in the pack while grid charging only weakens the strongest cells in the pack.
    There have been reports and pics of packs catching on fire while grid charging without air flow through the pack.
    For safety,
    USE a fan and a Thermocouple - Wikipedia - if you have one, or a thermometer to measure the inlet and outlet air temps while grid charging.

    Until you figure out how to adapt your Gen2 harness to your Gen3 fan, I'd suggest using an 3 socket extension cord to the grid charger and also plug in a household fan and run the fan pointed at the cooler intake.
     
    #3 vvillovv, Feb 26, 2021
    Last edited: Feb 26, 2021
  4. ASRDogman

    ASRDogman Senior Member

    Joined:
    May 29, 2018
    3,805
    2,267
    0
    Location:
    Florida
    Vehicle:
    2010 Prius
    Model:
    Two
    You could just buy the correct cable for your car.... :)
    That would be the safest way to do it.

     
  5. PriusCamper

    PriusCamper Senior Member

    Joined:
    Mar 3, 2012
    6,536
    2,752
    0
    Location:
    Pacific Northwest, USA
    Vehicle:
    2007 Prius
    Model:
    Two
    Because the price is a scam... It's a $149 for what? $10 of plugs, terminals, fuse holders, wires and a simple little $8 fan control relay box that they'll sell you for $15 if your original breaks?

    All the while Hybrid Automotive never gave credit and stole the designs for their system from the early day posts on DIY websites like Insight Central and here, which taught people how to build their own grid charger and variable speed fan control boxes that are much higher quality for less $100 total.

    I use to be a big fan of Hybrid Automotive, but the more their equipment fails and the more I realize how they skimp on super cheap parts and charge more than 10 times their cost to manufacture, the more I'm looking into building my own gear.

    First I need to read through all the old links again. Then I need to buy some of these to build a grid charger: https://www.mouser.com/ProductDetail/MEAN-WELL/APC-35-350/?qs=%2Fha2pyFadujitiXKI3Am59jVMxwoQShdVJfANkhx6fEbVL20LNBrEw%3D%3D
     
    #5 PriusCamper, Feb 26, 2021
    Last edited: Feb 26, 2021
  6. ASRDogman

    ASRDogman Senior Member

    Joined:
    May 29, 2018
    3,805
    2,267
    0
    Location:
    Florida
    Vehicle:
    2010 Prius
    Model:
    Two
    Oh boo hoo.....
    There's nothing wrong with YOU being cheap if you want too. And one mistake,
    and he could destroy the battery, and possibly injure himself.

    It's not a scam just because you say it is.

    You are not JUST paying for parts. You are paying for knowledge, and skill on how to use the
    correct parts in the correct way, and what parts to use. And having the money to do it.

    If you think you can come up with better, safer and less expensive way of coming out with
    a device that will do the same thing, go for it, mass produce it. Put them out of business.

    I'm sure many Prius owners would be happy to pay $300 to your company than $700 to another company.



     
  7. PriusCamper

    PriusCamper Senior Member

    Joined:
    Mar 3, 2012
    6,536
    2,752
    0
    Location:
    Pacific Northwest, USA
    Vehicle:
    2007 Prius
    Model:
    Two
    So it's good to pay thieves for knowledge and skill that they stole off DIY websites hybrid car websites and refused to credit the people most responsible for that knowledge even though their entire foundation of their for-profit business is built off that knowledge?

    A trickle charger and fan controller is basic electronics 101... Adapting these electronics to safely be used on hybrid cars isn't something hybrid automotive invented.

    And it doesn't have anything to do with being cheap, it has to do with not being a sucker who gets ripped off.
     
  8. ASRDogman

    ASRDogman Senior Member

    Joined:
    May 29, 2018
    3,805
    2,267
    0
    Location:
    Florida
    Vehicle:
    2010 Prius
    Model:
    Two
    Stilllllll waiting on the design......
     
  9. PriusCamper

    PriusCamper Senior Member

    Joined:
    Mar 3, 2012
    6,536
    2,752
    0
    Location:
    Pacific Northwest, USA
    Vehicle:
    2007 Prius
    Model:
    Two
    I've already read all the designs and have all the links, I just have to dig them up... @alftoy and I and a couple of my friends are working on component sourcing already.
     
  10. ASRDogman

    ASRDogman Senior Member

    Joined:
    May 29, 2018
    3,805
    2,267
    0
    Location:
    Florida
    Vehicle:
    2010 Prius
    Model:
    Two
    riiigghhhttttt....... only time will tell....

    Then it will be getting people to trust you....

    Then someone will accuse of doing what you accuse other's of doing.
     
  11. vvillovv

    vvillovv Senior Member

    Joined:
    Mar 19, 2013
    2,003
    725
    0
    Location:
    NY
    Vehicle:
    2017 Prius Prime
    Model:
    Prime Plus
    I only grid charged in the car once and it was during spring weather, but the car was in direct sun. At night temps were fine. But when the sun came out the temps went way past ideal for charge/discharge, even at the very low amp input and discharge load. The lower the input air temp, down to around 50 F or 10 C and the more stable you can keep that temp, the better the results, usually, at least in my experience.
     
  12. vvillovv

    vvillovv Senior Member

    Joined:
    Mar 19, 2013
    2,003
    725
    0
    Location:
    NY
    Vehicle:
    2017 Prius Prime
    Model:
    Prime Plus
  13. PriusCamper

    PriusCamper Senior Member

    Joined:
    Mar 3, 2012
    6,536
    2,752
    0
    Location:
    Pacific Northwest, USA
    Vehicle:
    2007 Prius
    Model:
    Two
    Some who talk to George there have done well, some not so well... If you can get him to sell you just the fan box for $15 for Gen 3 that's solves the problem real quick. Of course shipping anything to New Zealand is the opposite of quick.
     
  14. vvillovv

    vvillovv Senior Member

    Joined:
    Mar 19, 2013
    2,003
    725
    0
    Location:
    NY
    Vehicle:
    2017 Prius Prime
    Model:
    Prime Plus
    Agreed @PriusCamper , my initial thought was in a pinch Hybrid Automotive might offer an owner of their produce an exchange for the correct harness at a reasonable price, key is reasonable for both parties.

    I too am well aware of Mike and his programming friend in Canada, pioneering work with the Genisis One charger versions and Peter's work of the simple(r) charger and the many copies that have been made by current businesses and DIY enthusiasts that have made their own chargers based on the schematics Mike has posted. ;)
     
    PriusCamper likes this.
  15. PriusII&C

    PriusII&C Member

    Joined:
    Oct 15, 2013
    176
    66
    0
    Location:
    San Jose, California
    Vehicle:
    2012 Prius
    Model:
    II
    @vvillovv and @PriusCamper : I just started following charger topic as my Prii entered 8th years of age. I am not aware of Mike and Peter's work. Wonder if someone could post the links?
     
  16. vvillovv

    vvillovv Senior Member

    Joined:
    Mar 19, 2013
    2,003
    725
    0
    Location:
    NY
    Vehicle:
    2017 Prius Prime
    Model:
    Prime Plus
    Mike sold his Genesis One business to Hybrid Revolt and retired HybridReVolt: Hybrid Battery Repair
    Peter only sells his simple charger as a one to one transaction from the UK with other members of the insight central forum as far as I'm aware.
    Best I can do without a used by permission.
     
  17. PriusII&C

    PriusII&C Member

    Joined:
    Oct 15, 2013
    176
    66
    0
    Location:
    San Jose, California
    Vehicle:
    2012 Prius
    Model:
    II
    Thank you.
     
Loading...