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Charged HV battery with my gasoline generator :)

Discussion in 'Gen 2 Prius Technical Discussion' started by spoonertuner, Feb 11, 2024.

  1. spoonertuner

    spoonertuner New Member

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    This is my first post. I've been reading other threads for a couple weeks and thought I'd contribute something.

    I just finished replacing my head gasket. Then the car wouldn't start because the hybrid battery got drained too far over the last 4 months sitting their not being used. I scratched my head a bit trying to figure out how to recharge it. Then I realized I could use my gasoline generator, a large bridge rectifier, and some large capacitors to produce the higher DC voltage that I needed to recharge it. I already had used this setup before earlier on to charge my LiFePO4 lithium battery bank for my off grid solar system. Only difference this time was that I needed to adjust the generator's AC output voltage on its voltage regulator to produce just the right DC voltage I needed. It worked great!

    I set the generator to output 182v AC which produced 272v DC after going through the rectifier and capacitors. This is what was measured without any load on it before I connected it to the battery pack. My battery pack was at 218v DC when I first started charging it. I measured 240Watts of charging power after it started charging. I only charged it for maybe 5 minutes at the most which brought the battery up to 225v while charging. This was enough to get the car's engine started and allow it to finish charging the hybrid battery.

    The car charged the battery up to 242 volts DC after it started up. It's about 34 degrees here in Idaho so I didn't bother powering on the battery pack's cooling fan for only a couple minutes of charging. But this should be done normally if you charge for longer periods of time in warmer weather.

    The two capacitors I used were rated at 500volts and 8200uF. Rectifier was way bigger than necessary as I only pulled less than 2 amps through it. Generator is rated at 10kw.

    Anyways, thought I'd share this. I posted a Short video on YouTube but can't share it here yet. My channel name is SpoonerTuner and video title is "Charged Dead Prius HV Battery With My Generator"

    Hope this helps or inspires someone. :)
     
  2. Tombukt2

    Tombukt2 Senior Member

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    No I think a lot of people or some people have chargers I have a home generator but I'm not I don't think I'm going to build a bridge rectifier and all that so on and so forth just because but yeah that's really cool and yep you can absolutely do that I'm not sure how your battery is going dead in 4 months of sitting I walk up to generation twos put a 12 volt in the trunk car been sitting there for close to a year. Fire the car right up with the people standing there that have been told it's going to cost $5,000 to get the car fixed moved dealt with whatever and then drive it back to my place 45 mi away I own that car and drive it almost daily or my other half does. Just the other day I went to a towing lot and did the same thing with another generation too that had been sitting for 9 months I made the guy charge up the 12 volt that was in it because it was fairly new stuck it in the car car fired right up and it's got parts missing off of it people have taken stuff car fired right up backed up pulled back into the place it was and I asked the guy what's the problem? Now that you've sold all the parts off the car moot getting it started isn't it? Certainly not going to do anything with it with all these parts missing.
     
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  3. bisco

    bisco cookie crumbler

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    Well done! I don’t think I’ve ever run across something like this before
     
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  4. spoonertuner

    spoonertuner New Member

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    Thank you. Had to find a way to get it running somehow. haha

    That's awesome you were able to snag Prius up cheap and drive them off like that. I was hoping mine would have been an easy fix, but not so much. haha I'm having to fix/replace the head gasket, combination meter, HV battery and 12v battery. But, I've learned a lot in the process.

    As brainy as I am sometimes, I can over look the simplest things. haha Like you said, the HV battery probably was not the problem. The combination meter was one issue causing the gauges to not light up in really cold weather. But the main problem was that I didn't know how to start up a Prius correctly. I wasn't pressing the brake peddle before hitting the Start button. :( And the third problem that I caused for myself was that I didn't fully lock in the service plug grip and assumed it wouldn't make a difference if it wasn't fully locked down. I didn't have a scan tool the other day or I probably would have figure it out sooner. These Prius are a different kind of animal for sure.

    Now I have no more OBD2 codes or warning lights after I cleared the codes with my new bluetooth Panlong OBD2 Scanner and test drove it a couple times. I also tested the HV battery today with the Dr. Prius app and block #8 in the middle is out of spec and not charging up as fast as the other blocks do. And the entire battery pack tested with only 25% of its usable capacity left in it. So I'm going to pull it out and cycle the modules and replace any that don't come back up enough.

    I did order a MEAN WELL HLG-480H-C1400AB LED light power supply for $160 that arrived today to use as a charger. But they sent me the wrong one. It will charge at 480W and is fully adjustable for constant current and constant voltage. So, I can use it for a other non-Prius projects too.

    I also bought a HiTEC X4 AC PRO charger for cycling the individual modules.
     
    #4 spoonertuner, Feb 14, 2024
    Last edited: Feb 14, 2024
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  5. Tombukt2

    Tombukt2 Senior Member

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    Have no idea about any of that but I own a Venice hybrid charger that'll charge Honda batteries most all Toyota hybrid batteries and a third step for charging other hybrids as far as I know I've used it a whopping one time other than that I've never had to do any charging I walk up to these cars that have been sitting on the side of the road or in a driveway for a year throw a 12 volt in it even if the dash doesn't light up some of it will if the CM monitor or the gas gauge or the speedometer is bad We don't care hold the button down a little longer whatever that just gets it out of the driveway and to my house and then we'll decide whether we're stripping or fixing generally most of them have been fixed because there are one of the easiest cars on the planet to fix and one of the least cars needing to be fixed on the planet also until humans run them into the ground and then start thinking about what they need to do. So generally it all comes out in the wash Good show you got your car running and there you go now you have time to play with batteries and storage and all that and should work out reasonably well there's not really a lot to the generation too It's the later models that they kind of added all the hubbub to.
     
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