New Prius, Battery Recondition Idea After Reading Forum ALL DAY :)

So, I'm purchasing a new-to-me 2013 Prius Persona tomorrow and will be giving it to my 18 year son to take to college. I am an Automotive Technical Instructor Full-Time and 35 year Army Veteran (still in) Electronics Warfare Warrant in the National Guard. I have a electronics repair shop in my garage and fell pretty confident in my abilities. That being said, i wanted to run my idea past this supreme group.

I've spent all day watching every YouTube video and reading the pertinent threads here and want to go completely over the car before my son leaves for college (test/replace if needed 12 volt battery, test/recondition/replace HV battery modules, clean fan and inlet duct..etc).

When it comes to reviving the HV battery modules, the DIY process seems to include a RC battery/balance/charger/discharger. The recommended was the older 4X300 (due to firmware allowing discharge/charge totals being displayed on screen) or Charsoon Antimatter DC 4X300 (older firmware, but on backorder). The idea is to Charge @ 5A to 7500mA & Discharge @ 0.7-1A to 5.8VDC (albiet Hybrid Automotive goes down to 3.0 VDC (0.5 PER CELL - 6 cells per module). SO, since ONE of those 4 channel RC Chargers are about $200-240 US and there are 28 modules....it would take a while. I read a LONG thread (Dorman Part 2 I think), where a member did like SEVENTEEN cycles and brought almost every module back past 6500 mA each !. I've read up on the chemistry of NiMH and how the Prius ECU SOC/charging strategy isn't optimum for the battery energy density.

Anyway, to speed my process up and spend the SAME amount of money, could I use 14 IMAX B6 (I think they are clones of SkyRC B6) which are 80W Chargers and put to modules in series? (So, my charge would still be @ 5A to 7500mA (Say 16 VDC @ 5A = 80W) & Discharge @ 0.7-1A to 11.6 VDC (or 6 VDC for deep discharge like Hybrid Automotive does). This would allow me to do all 28 modules at once.

This seems feasible to me (kinda like the grid charger - prolong charger/discharger), but at a lower level (2 modules in series versus all 28 in series).

When finished, I could tie the POS & NEG in parallel fo an hour to balance (or longer if someone thinks longer is needed).

Thanks for any feedback,

Doug

 

Well, I tried to edit my above and could not see where to do that. After looking at the specifications of the IMAX B6, my main issue is the 5W discharge spec. That would limit my discharge to about 300 mA...way to slow. So, it seems like 2 Hitec X4 AC Pro's might be better.

 

Grit,

Thanks for the reply. Not sure what info posted led you to think the HV battery might not need to be reconditioned. My thought was that the battery is original (7-8 years old and has 155k miles on it). I did notice the dash MPG indicator says 42 MPG. Based on those two factors, I think a reconditioning couldn't hurt. (I've got a few months before he leaves for college...better for me to go through this vehicle completely before he leaves). I have Techstream, AutoEnginuity, Dr. Prius & Autel MP908P...Once we get through this "lockdown", I will perform a thorough HV battery test.

Now, you mention the EGR tube, I'm familiar with EGR's, their purpose and operation...I'm assuming there is something special/unique with these 1.8L's

155k, all original battery. Also, as just replied..the MPG info says 42 MPG (a "typical" indicator HV battery "might" be weakening).

LOL...reminds me of diesel EGR's and GDI intake valves. I did a quick search and watched a YouTube video. Piece of cake, I will be doing that as well. Thanks for heads-up.

BTW, is there a thread/document for new prius owners of things to look at/modify/update/repair?

 

BTW, I just ordered the Nickel-plated buss bars & nuts. I will be going through this vehicle completely before giving to son for college.

 

Yup, was you..great thread with detailed info

See above, not under warranty - 155k miles

See above, will be using various tools to test before making decision

Don't feeling like either spending that kind of money, also..buying a used pack still has possible different capacity issues. Once I get the vehicle and run the testing, I'll know more of course. The good thing is..I've got time. Son goes to college in August. This also allows me to teach him diagnosis/repair on his vehicle. Lastly, I'll know everything is as good as it can be before he leaves.

Yup, see above (my second post)...biggest drawback is the discharge rate (5W-10W). However, what I like about the HiTec is that is tracks and displays ALL the CHG/DSG amounts from the cyclic process. Lastly, has PC software for graphing.

Thanks for your input.

 

Just wanted to advise, this HiTec has 10W discharge per channel

Not dramatically important, but I'ma gadget and statistics guy..so it could be "neat" . I will contact company about SW and cable (I believe it's a standard micro USB to USB cable.)

 

I looked at the CQ3 as well, but could not find many that had them in stock. Do you think the specs of the CQ3 are better than the HiTec? I know one of the things people talked about in many of the threads was the accuracy (or lack of) the DCH/CHG readings between machines.

 

Rebound, my pleasure....I really enjoy the service. I also want to say I'm in the FLARNG now and my civilian job is a full-time automotive technical instructor for a OE/OES/AM parts manufacturer. So, I've got VERY strong electronics (Basic to RF/SATCOM) & Advanced automotive skillsets. I hope I can not only learn from the threads here (some are VERY long )....but maybe show some techniques to assist in quick diagnostics.

Well, I've just spent TWO full days reading MANY threads (some recommended by above conditions).

So far, I fell "spun-up" on the EGR/IM/OCC/PCV upgrade/maint service and what symptoms they present. Also, the head gasket concerns.

My HV (traction) battery concern and why I want to test, document, recondition is because:

1. It's the original - 155k miles
2. The fact that the Toyota ECU maintains 60% (+/-20%) in itself lends to degrading battery capacity (energy density).
3. My son will be 2.5 hours away @ college and I want to try and make sure this vehicle is "as good as it can be" before leaving in August.

I have the carfax and it appears ALL Toyota services have been done by the dealer religiously. I plan on calling the dealer with VIN and asking specifically what was done and mileage tomorrow.

You mention videos for the above...other than NutzaboutBolts YouTube channel, is there a link to them?

Thanks again for your reply !

Doug

 

Yes, careful...I took my professional scan tool & bought the Dr. Prius app and spent an hours scanning and testing the HV battery before paying for the car. Even brought my 12VDC battery tester to test the AGM (that's a $160-200 battery). Found the AGM bad and the HV battery had a 72% battery life (pretty good and the maximum module-module voltage deviation was 0.16 VDC.

Joe, just picked up car last week. Bought the HV fan filter off ebay (it did not have one installed). Bought the nickel-plated bussbars and nuts off Amazon and ended up with the Hitec X4 AC Pro charger as mentioned above. I have a snapshot from my scan tools as to the individual module voltage levels and will be reconditioning then in packs (2 modules in series). I can do a video of the process if you desire (not sure you electronic knowledge).

Since the son doesn't need the car till August, that give us plenty of time to do all the additional maintenance/upgrade work I want to do. I've ordered/received and will be installing/cleaning:

New EGR valve (bought from Japan for $140 new - OE)
Clean EGR Cooler & Intake manifold
Replace plugs
Clean Fuel Injectors
Clean MAF
Change oil and install Fomoto F103S drain valve
Drain & fill transaxle
Drain & fill engine & inverter coolant
Replace cabin air filter
Upgrade headlights to LED
Replace PCV & install catch can
Replace radio (Pioneer DMH-2660NEX), speakers & add a Pioneer TSWX130TA Subwoofer under seat

Good luck with your vehicle !