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Ok to use electric fence wire to balance HV battery pack in parallel?

Discussion in 'Gen 2 Prius Main Forum' started by nathandavidhall, May 27, 2022.

  1. nathandavidhall

    nathandavidhall Junior Member

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    Hey all, I've been slowly trying to get a '07 Prius back in driving condition after it gave me the red triangle etc over a year ago (buying a '21 Prius Prime kinda hurt the motivation haha). I've got the battery out, found the 5 bad modules, replaced those with good (hopefully) modules from ebay, but the replacement modules measure about 7.7v while the rest are around 7.3v.

    I understand I should balance the whole pack by flipping every other module so all positive are on one side and all negative are on the other side, then put a wire across all the positives and a separate wire across all the negatives. I read that a solid copper 12 or 14 gauge household wire is best but a coat hanger can work.. My question is, can this 14 gauge galvanized electric fence wire work just as well? I have a bunch left over from another project and it'd be the easiest thing to use.

    I'm hoping to not have to use an RC charger and all that, the only charger I have currently is this 6v/12v car battery smart charger. Really hoping I can just slap some wires on there, give it 24 hrs to balance, put it back in the car and hope for the best. Thanks!
     
  2. alftoy

    alftoy Senior Member

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  3. dolj

    dolj Senior Member

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    You understand incorrectly, that process is called equalizing, not balancing, and is largely a waste of your time and effort.

    To balance the battery or separate modules you need to do a series of overcharges (at a very low current) and discharges (to lower stopping voltages on each subsequent discharge) finishing with a gentle final overcharge.

    If you want to balance the battery, there is no getting around using a charger and discharger.

    You might be able to get away with doing a 'top charge' which in essence is just doing the first balance charge and then stopping.
     
    jerrymildred likes this.
  4. Tombukt2

    Tombukt2 Senior Member

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    You should see the tiny Little liars on my Venice hybrid multi-volt charger which goes from around 175 to 400 volts I have a switch on it because the wire is not carrying any amps it's only carrying milliamps so the wires could be Jesus I probably 18 gauge looks like what these are on this charger and it's pretty well built too so I would think you're 12 gauge any kind of copper wire would be suitable on down to around well at least 14 but like I say my charger this thing looks like 18 gauge wire it's very thin is not made to handle any amps milliamps probably I know my charger is 2,400 milliamps at 336 volts
     
  5. nathandavidhall

    nathandavidhall Junior Member

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    Hmm so there's no advantage to "equalizing" in that way? I came across it a few times on blog posts and such but I guess it was from other folks who were less informed. I think I've also seen threads where people just put the battery back in the car after replacing modules even with slightly different voltages, is there a chance I can just put it back in with the 7.3-7.7v difference and be ok?
     
  6. dolj

    dolj Senior Member

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    By slight, I would expect that the voltages would be 0.1 - 0.2 volts variance.
    I wouldn't, but until you charge them all up and do a load test (or let them sit for a week) and see what the variance is, no one can really say. If it is more than 0.3 V, I wouldn't expect the repair to last for very long before throwing a code.

    The key to good repair is having 28 modules that are closely matched (both capacity and charge/disscharge characteristics) to each other.