See:

https://www.greenhybrid.com/forums/f...98/#post266456

The following power supplies:

https://www.mouser.com/ProductDetail/709-LPC100-350

and

https://www.mouser.com/ProductDetail/709-APC35-350

Wired with output in series and input in parallel can provide up to 386V of 350mA charging to the FEH battery. That should be more than sufficient to obtain true 100% SoC. Optimally, the pack would need to be cooled in a way that simulates its normal cooling system operation to ensure the pack doesn't overheat. If the cover is off, and a box fan is placed face down on the pack, that should be sufficient. NEVER charge to full without some form of cooling. Charging for 8 hours or less from a KNOWN EMPTY battery can be done without cooling.

Use 3 light bulbs wired in series to DISCHARGE your pack to progressively lower levels over a long period of time followed by a very long charge (25 hours).

Steps:

1. Charge for 25 hours
2. Discharge with 3X 100W bulbs in series to 250V, record discharge time to 300V
3. Discharge with 3X 40W bulbs in series to 200V (swapping the bulbs will cause a voltage bounce. Normal)
4. Charge for 25 hours*
5. Discharge with 3X 100W bulbs in series to 250V, record discharge time to 300V
6. Discharge with 3X 40W bulbs in series to 125V (swapping the bulbs will cause a voltage bounce. Normal)
7. Charge for 25 hours*
8. Discharge with 3X 100W bulbs in series to 250V, record discharge time to 300V
9. Discharge with 3X 40W bulbs in series to 125V (swapping the bulbs will cause a voltage bounce. Normal)
10. Charge for 25 hours*
11. Test drive.

*charging with these power supplies from low voltage can be problematic. Since they auto-adjust voltage to regulate the 350mA current flow, they aren't often in sync. You may want to make provisions for taking the APC-35-350 out of the circuit until 286V is reached. Charge time of 25 hours is assuming 350mA of actual charge current. If you get less than that, you need to charge for longer.

A harbor freight cheapo multimeter in 10A mode in series with the charge/discharge (NOT DIRECTLY CONNECTED TO THE BATTERY TERMINALS!!!!) would allow you to compute charged/extracted capacity over time and actually estimate pack health.

The above process will take you about a week and cost you about $75. It will either work, or it won't. Consider that you will be exposing yourself to potentially lethal voltages. Do so at your own risk.

Good luck

 

I'm curious why you would recommend the two 120VAC chargers, rather than the 220V 150-350?

 

Where do you live?

 

San Diego

 

Since you are in America, you do not have access to single phase 220V, hence my recommendation.

 

Awesome timing. I just bought a high mileage escape hybrid and was looking for resources to build a grid charger. I've built dozens for the 1st gen Insight. That link you gave is perfect. As for battery cooling while discharging. Why not connect the built in fan to your charger with a seperate switch and 12v (guessing its 12) supply? It would allow you to install the wiring and not have to keep everything open.

Thanks for the writeup.

 

Because, like almost every fan besides the G1 Insight, they are PWM controlled and can't be driven simply by applying a voltage.

Cooling during discharge is not necessary. I have clarified my original post.

 

Awesome thanks

 

Very valuable info here!
I bought a single Meanwell HLG-185H-C500A
from Mouser in ON, arrived next day and was CAD$86 (faster and less than amazon)
400vdc out @ 0.5A (current is adjustable) 200W power supply.
I cut a computer cord in half, wired the plug-in part to the HLG-185H-C500A. The socket half I wired directly to the hybrid battery terminals at the contactor, and drilled a hole so it can hang outside the hybrid battery case. I plan to leave it (taped up well as it is a safety hazard!)
I'm charging now, and will build the discharge light bulbs today.
Be careful with these circuits, they are 400 volts DC and very dangerous. Think twice and there is the power to kill you coming from both ends so if you're not an expert at this, don't play around with it!
I have 7-8 FEH batteries to play with and 2 running FEH.
Global Hybrid in ON is advertising a 1 yr warrantee battery for CAD$1300, and they basically just do this charge/discharge to recondition them. And the Chinese sites will sell you Nimh sticks for USD$2000... too rich for me as these cars are 17-18 years old...
I did rebuild a 2005 engine (spun bearing) the 2.3 Atkinson. Needed a crank, cams, 1 rod, and bearings. Parts are cheap and I got the intake cam from the junkyard as the Atkinson cam is different. Nobody had the torques for the mains and rods - saying its unrebuildable - so I guessed at it. Seems to work as I put 100k mi on it since. Never took off the head, was able to pull the piston out the bottom to swap the spun rod.