PHEV Conversion #90? something almost done…
UPDATE 05/12/08: Yes, so far we made the TOP 100 PHEV list, we are so far Number 98.
I spent last Saturday & Sunday finishing up the PHEV conversion. It went pretty slow but it sure is great to actually enjoy the finished product. I still have some minor things to do but the Orlando Hamfest is this coming weekend so they will have to wait until next week.
First I finished installing the HV contactor enclosure and the regen-diode/ 60A @ 500VDC saftey fuse. I got it from McMaster-Carr, $22 for the fuse and about $15 for the holder. BUSS J60060-1CR for the holder and the fuse is a AMP-TRAP 2000 with “smart spot” AJT60 from Ferraz-Shawmut, a very nice combo.
The red Anderson connector is to the HV Battery Charger which I’m building right now. Here is a picture of the full PHEV battery pack and control boxes. The battery I chose was the AGM 18Ah Battery from MK, part of East Penn / Deka company http://www.mkbattery.com/images/ES17-12.pdf
I whipped up a temporary battery charger to use until I get the MPU controlled system built. It runs right off the 120VAC line using a voltage doubler with the current limited by the capacitors. I use a fan speed control to set the float voltage. It works okay but I want to properly charge the AGM batteries with the Bulk/Absorb/Float method as recommended. Charge current is about 4.5A @ 50% DOD and tappers to 1A @ 90% Charge, not bad for a non-intelligent charger.
The real-deal will look like this:
As soon as I hear back on my “official” conversion number I will update this section.
Prius Conversion #2 coming Summer 2008.