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Installed kit from Plug in Supply getting 28 miles!

Discussion in 'Gen 1 Prius Plug-in 2012-2015' started by jim335, Oct 6, 2012.

  1. John H

    John H Senior Member

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    That is an interesting approach, using each 120V leg seperatly to drive each charger. The pilot signal from the PiP could be passed through to the EVSE to activate the circuit.

    An alternative would be to connect the leads for the PIS charger between the J1772 connector and the PiP's onboard charger and "steal" some of the available AC charging current. Since most L2 chargers will provide 3.3kw or more, you should experience full speed charging for both battery packs.

    Does the PIS charger handle both 120V and 240V?
     
  2. JamesBurke

    JamesBurke Senior Member

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    I was referring to adding an aftermarket battery to the standard HV model.

    As for tapping lines on the PIP. The EVSE tells the onboard battery charger (BMS) how much current is available from the mains via the pilot signal. The BMS regulates the current drawn by the charger to be below this value. As the BMS has no way to monitor the additional current drawn by the added charger and adjust for it you could easily exceed the current rating of the main input.

    A control strategy that might work is to monitor the current being drawn by the PIP BMS and use any excess current below mains max to charge the added battery. Some hacking EVSE pilot safety switches on the car side would be necessary to keep the EVSE connected after the PIP BMS completed its charge.
     
  3. John H

    John H Senior Member

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    I re-read some of the earlier posts and it seems that the PiP's charger cannot draw more than 3kw and the PIS not more than 2kw. All of the public L2 chargers in my area provide 7.2kw. You are correct though that the combined setup should comply with the J1772 protocol and not draw down more than the pilot signal indicates. I doubt the PIS kit already has the logic to integrate with the J1772 protocol so an external adapter with some added logic would make more sense, albeit clumsy.
     
  4. jim335

    jim335 Member

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    The kit I installed is only for the plug in.
    Plug in supply already makes a kit for the regular prius and you should contact them for details.
     
  5. jim335

    jim335 Member

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    You are correct, the prius can not deal with having a second battery hooked ut to the on board prius charger. It shuts down thinks something is wrong and shuts down before charging gets anywhere.
    For now it is better to leave the car alone. I really liked being able to add the kit without modifying the car, safety parameters, logic and so on.
    The extra charger is no big deal.
     
  6. jim335

    jim335 Member

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    The plug in prius uses shielded conductors for the ac giong from the J1772 plug to the charger in the car with shielded connectors inside the car. To tap into that ac for the added charger properly would require a custom adapter plug to be put in series at one of the connectors, to tap off of. The other point is that the level II is controlled by the state of charge of the prius battery. The easiest way to deal with that is to buy an add on charger with the capacity to finish charging the add on battery before the prius battery is finished. The battery management system for the add on battery automatically shuts down just that charger when the add on battery is evened out and fully charged, at that point the prius charger could continue to charge the car battery until done.
     
  7. priuskitty

    priuskitty PIP FAN

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    Hi Richard,
    The Price of the battery pack is 1764USD,for the shipment,it should be 450USD.

    crystal

    From:RICHARDZIMMERMAN <[email protected]>
    To: 孙艳 <[email protected]>
    CC:
    Sent: 2012-09-29 10:20:38
    Subject:RE: Headway lithium battery

    Crystal,

    how much for the kit? also, how much to ship to 255 west 14 mile road, apt.1402, Clawson, Michigan 48017?

    [​IMG][​IMG][​IMG]Richard


    Date: Sat, 29 Sep 2012 09: 28:04 +0800
    From: [email protected]
    To: [email protected]
    Subject: Re:RE: Headway lithium battery

    Hi Richard,
    I'm glad to receieved your reply.
    I know the company called Plug In Supply,They are also one of our customers,and we can supply you a 4kw battery kit with connecters and holders.
    If you need any other information,please tell us,thank you!

    Best Regards
    Crystal
    From:RICHARDZIMMERMAN
    To: 孙艳
    CC:
    Sent: 2012-09-28 20:29:38
    Subject:RE: Headway lithium battery
    Hi Crystal,
     
  8. rockfeller

    rockfeller Junior Member

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    Checked headway-ch.com, I do not see 4kw battery under their Electric Vehicle section.
    Looks like this could be custom made battery to meet US consumers ?.
     
  9. jim335

    jim335 Member

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    Photo of install, just laid everything in the back. All connections are made to the car and is working. prius low angle.JPG
     
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  10. jim335

    jim335 Member

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    This is the install with all wires run properly. Relay and control board hidden away. To remove, unplug green connector on left first. Unplug red and black connectors on right. Unplug bms loop wire. Lift out both battery packs, that's it. prius finished.JPG
     
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  11. John H

    John H Senior Member

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    looks fairly clean. any way to secure the batteries? It looks like there are tie-down loops on both sides.
     
  12. jim335

    jim335 Member

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    Yes those are tie down loops. Nice of Toyota to put them in just the right place. Toyota even gives you a strap, which they tell you to use if you lay a spare tire in the back, which will work great.
     
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  13. 9G-man

    9G-man Senior Member

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    Very nice job jim335 ! I am familiar with the very good folks at Headway-cn.com. and particularly interested in this install.
    About a year ago I converted an electric Go-Ped scooter to LiPo with those same Headway batteries, connectors and holders. Much smaller in comparison, but similar setup, I'm familiar with what it takes........

    Now I want to build a couple monster packs for the PiP, like yours!

    [​IMG]
     
  14. rockerdan

    rockerdan PiP Rocks!

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    thanks for pics! looks awesome
     
  15. rockfeller

    rockfeller Junior Member

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    Thanks jim335 for sharing, this looks clear,.But where did you hide controller and relay ?.
     
  16. jim335

    jim335 Member

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    Under the trim in the cargo area, and in the storage area behind battery. control board stored.JPG
     
  17. jim335

    jim335 Member

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    BTW, I want to see if parts sells just the cover that I removed. If so I will cut it to fit around wires and save original for if I want to put car back to original condition.
     
  18. rockerdan

    rockerdan PiP Rocks!

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    got a pic of where you plug it in?

    does your EV range double or how do you know how much battery you have left ect? just need more details.

    thanks!
     
  19. jim335

    jim335 Member

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    I used to get slightly over double what the car indicated after a charge. Instead of 12 to 13 I was getting 25 to 28. One interesting thing is that every time I charge up the car, the computer is slowly adjusting it's estimate of what I will get. It is now up to 16 miles estimated. I will be interested to see if it eventually reaches the amount I actually am getting. I am not actually getting more than the 25 to 28 that I was before though.
     
  20. rockfeller

    rockfeller Junior Member

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    Toyota computer is PiP learning slooowly ...:).