Saturday, October 31, 2009

New batteries & battery heater pad

Today I performed a temporary install of the 4 new batteries I've purchased for the Honda. These are in addition to the 6 it already has, thus making it a 120V system with ~12kWh pack (2o hr. rate). These four batteries plus the other two under the hood will be charged by two Dual Pro Recreational Series 3-Bank 6-Amp chargers. Each charger has 3 independent, isolated, microprocessor-controlled chargers capable of pushing 6 amps, which may be used in series or in parallel with each other. Here's a picture of the batteries wired up into a temporary 48V bank, with the Dual Pro chargers sitting next to them.


Also, I found out about a very economical way to control the temperature of batteries being warmed by battery heater pads: Water heater thermostats. These thermostats switch 120V AC, and handle the wattage of normal hot water tank heating coils. Perfect for the battery heater pads I've bought, which don't come anywhere close to the wattage of a hot water tank. And they cost less than $10 each, so you can afford to put one on each bank of batteries you'll be heating. That's important because different banks will have different thermal properties depending on their isolation from the outside environment. Here's a picture of a water heater thermostat I bought at Lowes, sitting on top of a Farnam battery heater pad I bought from KTA Services. The thermostat can control in a temperature range of 90'F - 150'F. Which is fine for lead acid batteries, since you probably want them warmed to about 100-120'F for best performance.


One thing Dave Cloud warned me about with the hot water tank thermostats, is to do one's best to isolate the thermostat from any possible gas the batteries might vent. This is due to the possibility that the contacts inside the thermostat could spark when making/breaking the circuit, which could ignite a concentration of hydrogen gas. While I assume this is more of a concern for flooded batteries than the AGMs I'm using, it's a valid point and one I will have to consider.

Saturday, October 10, 2009

New 4-Bank 10-Amp charger



Today I installed a new charger on the 4 batteries in the rear of the Honda. After looking a long time, I found a really good deal at ChargingChargers.com on the Dual Pro Sportsman SS4. This is a 4-bank, isolated, microprocessor-controlled 12-48V charger, which may be used as a single 12V-40A unit, 24V-20A, or 48V-10A, and so forth. It has a 3 year warranty. According to the box, there are 750,000 Dual Pro units in the field, and they tout being green by virtue of being 100% repairable, NOT disposable. Made in America.

I installed this charger to replace the four Soneil 1206S chargers that had been on these batteries before, two of which failed this summer during the hot weather.

Thursday, August 20, 2009

Battery Cost Analysis

I've been encouraged to post my recent evaluation of the cost of various models of traction batteries for EVs. I basically ran the numbers three ways, to answer three different questions:

1) What is the cost per mile to use a particular type of battery? This is answered by the "Total, cents/mile" row under the "System Detail" section. I didn't include the cost of support systems such as charger or battery balancers because, although they may cost more for one type of battery than for another, they are a fixed cost and don't need to be replaced when the battery pack is replaced.

2) What is the overall cost to use a particular type of battery for 120,000 miles? This is answered by the "Cost, $ (incl. electric)" row under the "120K miles" section.

3) How far can you drive on a particular type of battery before you exceed the cost of buying Lithium batteries at today's prices? This is answered by the "Total Miles" row under the "Equal Lithiums" section.

The Range figures were obtained from EV Calculator, using a '92 Metro, ADC FB-4001A, Kelly controller, battery specs available online, Range calculated to 80% Depth-of-Discharge, and a driving mix of 85% @ 30-40mph in 2nd gear and 15% @ 60mph in 3rd gear.

Here are my calculations. I'll let you interpret the numbers as you like. Sorry it's showing up triple-spaced; I can't find a way to correct that.

Cost

Battery Mftr / Model

Analysis

Prices as

Optima

Trojan

Discover

Sky Energy

of 6/15/09

D34M

T-1275

EV31A-A

SE100AHA

Battery

Detail

Chemistry

SLA-AGM

FLA

SLA-AGM

LiFePO4

Cost, $

188

200

490

121

Source

amazon

batteriesin

batteries

evcompo

.com

aflash.com

direct.com

nents.com

Voltage, V

12

12

12

3.2

Weight, lbs

43.5

84

74.1

7.04

Capacity, Ah

55

150

115

100

System

Detail

#(batts)

12

10

12

45

Voltage, V

144

120

144

144

Pack cost, $

2256

2000

5880

5445

Capacity, Wh

7920

18000

16560

14400

Weight, lbs

522

840

889

317

Range, mi

25

40

35

60

#(cycles)

600

600

600

2000

Miles/pack

15000

24000

21000

120000

Electricity, $

428

972

894

2592

(@9¢/kWh)

Total, ¢/mi

17.9

12.4

32.3

6.7

120K miles

#(packs)

8

5

6

1

Total miles

120000

120000

126000

120000

Cost, $

21469

14860

40645

8037

(incl. elec.)

Equal

Lithiums

#(packs)

3

3

1

1

Total miles

45000

72000

21000

120000

Cost, $

8051

8916

6774

8037

(incl. elec.)