Repair of a high-voltage battery of a hybrid car
The high-voltage battery (HVB) of a hybrid car is one of the most expensive spare parts, so its replacement can hit the car owner’s pocket hard. But there is always the opportunity to avoid small losses and repair the battery of a hybrid car or electric car.
Our service center offers the most efficient repair of a high-voltage battery, which includes in addition to replacing faulty battery balancing elements on a special stand.
Hybrid car battery repair includes several main areas of work:
- battery equalization;
- removal of HVB;
- connection of loading and measurement of indicators of the battery;
- rejection of defective elements;
- replacement of defective elements;
- balancing the battery of a hybrid car;
- HVB installation.
Equalizing a battery of a hybrid car is a process of long-term charging of the battery by the engine to the level that can give the maximum battery. During this process, each element of the car’s high-voltage battery is charged. Serviceable elements charge quickly enough, faulty or “tired” longer. You can start the equalization process after connecting to the car. At the same time you can see how worn out the battery. With the help of the scanner you can see the difference between the maximum and minimum charged element, if this difference does not exceed 20%, the battery is in normal condition and equalization will improve its performance. But if more than 20% difference in charges, it is worth thinking about repairs.
It should be remembered that weak elements wear out faster than normal and if you do not immediately replace 1-2 worn bamboo, then you will need much more.
Removal and disassembly of HVB is a matter of technique and experience. The main thing is not to forget to use service Switches during dismantling of HVB and to unscrew all necessary bolts.
After removing the battery, it is connected to a special stand. The stand is a two load Tena, one of which is high power, the other – low, a set of digital voltmeters. Each of the heaters has its own switch.
To begin with by means of a loading fork the battery to 140 V is pushed. This value is convenient for a set from 20 bamboo. In a normal battery, each bamboo would have a voltage of 7 V. But in a faulty battery, the situation is a little different. After applying the load, it is necessary to turn off the powerful heater, while the small heater does not turn off. Then with the help of a digital voltmeter voltage measurement is performed on each element of the battery. The obtained values are entered into the diagnostic table. The difference in voltage in normal elements is one hundredth or, at most, tenths of a volt, but faulty elements differ by 1-2 volts.
An important condition is the speed of measurements, if they take more than 1 minute, they are not objective, and therefore will not allow you to properly repair the battery of a hybrid car. In both blocks of the battery it is necessary to push elements to the same size.
After the measurements, we select the reference element, which we will focus on in the process of rejection. Then replace the faulty elements.
The next step is to select a pair of elements. The average value of a pair of elements should be equal to 7 V. This is one of the most important stages of repairing the battery of a hybrid car. Then you can proceed to the stage of assembling the battery. Here it is important not to confuse the polarity of the elements to avoid short-circuit HVB.
When disassembling and installing the battery cells, pay attention to the temperature sensors and their latches. It is necessary to connect and disconnect temperature sensors only in half of the removed elements. And before closing the battery cover, be sure to put all the latches in place so as not to cut the wires of these sensors. Next, assemble the battery in the reverse order of its disassembly, carefully connecting all sensors and tightening all bolts and screws. Then install the battery on the car and connect.
The last stage will be the equalization process, which will show how competently we repaired the battery. After equalization, the process of initializing the battery is started, after which you can only remove errors with a special scanner.
For example, there is a special load test for the Toyota Prius. Its essence is to accelerate the car to 128 km / h, while the voltage in pairs should not fall below 12V, and the voltage difference is not more than 20%. The battery icon should not go yellow. Successful passing of such test will testify that the high-voltage battery of your hybrid car was successfully repaired.
Our Car Service is waiting for you to repair HVB. Our specialists have the necessary knowledge and experience, as well as special equipment for servicing hybrid cars and electric vehicles.