Help with HV battery reconditioning

Discussion in 'Gen 2 Prius Technical Discussion' started by VeselyDM, Feb 21, 2016.

  1. VeselyDM

    VeselyDM Junior Member

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    I thought I had done enough research and knew what I was doing but I am not getting the expected results. This is my first posting. However I have been reading chats for sometime. Based on reviewing several of the theads pertaining to reconditioning the HV battery, I purchased 3 IMAX B6 chargers and have reconditioned 6 of my 28 NiMH batteries in my 2005 Prius with 170K miles. My concern is that I am not getting enough mAH after the third cycle.

    Background:
    - No fault codes before starting this project (170K miles, 2005)
    - With one of the buses disconnected, all voltages were between 8.04 and 8.08 Vdc
    - 6 of 28 batteries completed
    - HV battery is in the car, external fan is on to circulate air during charging

    Charger Settings:
    - NiMH Sensitivity - D. Peak Default (believe this to be 4mV/cell)
    - Waste Time: 20 minutes
    - Safety Timer - On set at 120 Minutes (6500/5A/11.9)
    - Capacity Cut out 7200mAH
    - Input Power low 10V C/O (believe this not to be relevant - voltage into the charger C/O)
    - USB/Temp Set Temp C/O 80C (I am not using temp C/O - this is the default)

    - DCHG>CHG 3 cycles
    - NiMH CHG 5.0A
    - DCHG 1.0A to 6.0V

    Results:
    - Takes about 10 hours to cycle 3 times
    - After the third cycle, the CHG values are around 3200+- 500 mAh
    - mAh tend to decrease slightly for DCHG (~50mAH) and decrease more for CHG (~700mAH) through cycles - resulting in lower mAH???
    - Individual voltages of the 6 charged batteries are around 8.50V and settle out at around 8.15V (higher than initial values.
    - All of the batteries (6 of 28) respond consistantly to the reconditioning process (CHG/DCHG mAH decrease??, increase in resultant voltage, amount of time 9-10 hours)

    Problem:
    It seems like the capacitance is decreasing through the cycles and my ending capacity is far lower than the rating of 6.5AH which leads me to believe that my settings are not correct. Assuming that my batteries were good to start because since I didn't have any fault codes and the initial voltages were consistant and above 8.0V, I decided I need some advice before I continue.

    Specific Questions:
    1. Are my setpoint correct?
    - Should my NiMH Sensitivity D. Peak be set higher (believe default is 4mV/cell)?
    - Turn off Safety Timer?
    2. Other threads discuss ending mAH being above 5000mAH. How do I get higher mAH?
    3. Should I CHG>DCHG three cycles to check mAH first, then perform the final CHG? This would enable me to deterimine the capacitance of the battery before the reconditioning starts.
    4. Why would my mAH for DCHG and CHG decrease though this process?

    Thanks for your assistance in advance
    VeselyDM
     
  2. VeselyDM

    VeselyDM Junior Member

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    Keith, thanks for the quick response. I looked into the Reaktor as recommended. Looks like it doesn't have a plug in for AC/DC power cable. I assume this is why you recommend the battery and the charger. I have the charger. If Reaktor powers off 12Vdc, why do I need the battery....go between? Battery charger to the battery to the Reaktor charger? Can you recommend a balancer that uses AC/DC converter so I can plug into a wall outlet - may save me som $$ in buying a new battery. Thanks. Dean
     
  3. jeff652

    jeff652 Senior Member

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  4. VeselyDM

    VeselyDM Junior Member

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    Thanks. I'll give it a try and return the B6's.
     
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  5. jalo

    jalo New Member

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    So I have entered the realm of Prii afterworld with scant disposable budget to bargain with its god to bring back our girl. Couldn't have started the journey without insights gleaned from the Gen 2 oracle. Trust me, it has been blessing and a curse. Take heed Mr. Keith's admonition of the perils that lurk! Especially 6 A charger island where I marooned, it seems, years or more. (Or perhaps a week or two but more than enough.) How I regret but lets start at the beginning. Our girl was taken by the Pri Underlord last spring to bedevil us from the Dealer's Half-Life. We couldn't pay the ransom at the NHW-20 crossing, but found a junkyard whisperer. She ran, heart revived, until winter's cold set in. That's when we became careless and let her sit idle a month or more, outside, and lavished attention on the new Jeep! Now both her heart and her donor's inhabit the laundry-room turned lab. Anyway, thanks guys! (I think.;) )
     
  6. VeselyDM

    VeselyDM Junior Member

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    Seems like I have had success in reconditioning the HV. Discharged and charged three times with Hybrid Auto kit. Final voltage on charger was 238VDC. I connected the ground strap from the aux battery to the car, attempted to start the vehicle and I can't get the car out of "N" (won't go to "D" or "R"). Hybrid Auto kit directions implies that a reset of the hybrid system is required. Any thoughts.
     
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  7. jeff652

    jeff652 Senior Member

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    Maybe this is too simple, but did you try pressing the Start button twice? It must be pressed twice (about 10 seconds apart) after the battery reset to get the car into Ready mode. After that the normal single press is enough.
     
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  8. VeselyDM

    VeselyDM Junior Member

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    Ended up being the aux battery voltage was too low. Good test diagnostic on YouTube.
     
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  9. Travis217350

    Travis217350 Junior Member

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    Hello,

    My name is travis. I tried ordering Prius king book reconditioning Hv batt from amazon. After a few days I get message saying there on back order no time frame. It's weird cause on amazon it shows that they have a few then gets canceled by seller.. Anyway here goes I have 04 Prius and purchased recondition battery so my car would be back on road ASAP. My old Hv batt has a few modules need to be replaced.I just bought 4 hitec x4 ac plus four port ac/D.C. Chargers to do rebuild job. I ordered the Chargers when I ordered the book. Since I can't get book I turn to you fellow members. I know I'm probably beating a dead horse and there's been multiple post on it. I have a probostion for one you if you can walk me through it step by step in baby language. From dismantling batt to testing each module then cycling from discharge to charge on hitec x4 battery charger and balancer. I went ahead and bought five new modules from eBay to have on hand for procedure. If anyone wants to take time to explain in depth on email or if someone has the book they can share with me. I don't want to be a nuisance so I'm willing to give somebody $100 in there PayPal for time rendered thank you in advance .
     
  10. strawbrad

    strawbrad http://minnesotahybridbatteries.com

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    You are better off without that book. This has been covered over and over again here. Read! Read every post made by member S Keith . He runs PHOENIX HYBRID BATTERIES . You are very lucky to live in his service area. You should have just gone to him to start with. Don't expect him to teach you how to rebuild a battery for $100.

    Here's one safety tip. Until all the bus bars are removed from one side of the battery high voltage is present. While removing those bus bars high voltage is present. "High voltage" is just a nice way of saying deadly.

    Brad
     
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  11. ericbecky

    ericbecky Hybrid Battery Hero

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    The nice thing about accidentally touching the full 220vdc high voltage is it tends to take you out pretty fast. Only painful for milliseconds before you go to meet your maker.
     
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  12. ozmatt

    ozmatt Member

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    < this (y)


    I thought with DC it kind of clamps on leaving its victim stuck holding on to get full effects of a slow painful cremation like experience .. (n)
     
  13. ericbecky

    ericbecky Hybrid Battery Hero

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    Hmmm... Maybe I've got that wrong.
    Could you quick do a test and then letreport back? ;-)
     
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  14. ozmatt

    ozmatt Member

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    LOL NOooo! ..

    As I understand this, alternating current gives a chance to "let go" between cycles but dc being constant just frys you crispy with one nice big contraction .. However I think more DC current is required than AC at the same voltage so both are perhaps equally fatal in different ways.

    Not sure how "fast" "it" happens, I suppose your stuck there until either you frizzle up and loose conductivity - or the battery goes flat

    Used to test 9v batteries on my tongue :) bad habit that
     
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