HV Battery Jump

  #1  
Old 12-25-2016, 11:14 AM
Ridiculously Active Enthusiast
Thread Starter
Join Date: Sep 2014
Location: Mesa, AZ
Posts: 2,921
Default HV Battery Jump

Regardless of what your 2008-2009 Owner's manual says, based on my research it appears that for MY 2008+, the HV Battery jump start system was removed. One can find online references where Ford claims it was never needed. Bullsh1t.

Please check this thread:

https://www.greenhybrid.com/forums/f...-button-31047/

I have included pictures showing a large piece of electronics missing from newer packs.

Furthermore, you can conduct your own grid charging with a little elbow grease.

For the love of all that is holy, make sure the safety plug is completely out. Even in the unlocked position, it is still making the connection.

The cover can be removed in-car with a little trickery. There are 2X Torx bolts on both sides of the cover that are essentially inaccessible. If you lift one side of the pack and rotate it about 15-20 in the compartment, you can access the two side bolts. These should be done first. Then remove the remaining T30 (I think) Torx security bolts.

From that point, one can access some live terminals with a little effort.

You can also check the 26 sticks at the top of the pack by probing through the shrink wrap. Anything less than 4.8V between the ends is completely dead. They should be over 5V, and they should all be very nearly the same - likely less than 0.02V deviation.

First, remove the 3 screws mounting the ECU on the passenger side. Disconnect all connectors and remove it completely.

Second, remove the main relay. This entails a couple of 10mm bolts mounting it into the case, a single 8mm bolt to remove a small plastic cover, 2 8mm bolts connecting the relay to the main plug and the two 10mm bolts at the orange blocks. Note that these are NOT hot. They are insulated from the live terminals by a ceramic insert. In order to get enough clearance, I also removed what looks to be a large ceramic resistor from the back of the relay attached with a T30 Torx screw. The Relay can then slide straight back. You will need to push wires and bundles down and out of the way to make it slide smoothly.

Flip the relay upside down and remove the two T30 Torx screws:



Then take off the top cover (the bottom cover is loose but retained by wires). The two points at which you can make your connections are here:



You then need to re-install it by sliding the forks back into the orange terminals and CAREFULLY tightening only the two 10mm bolts. You only need them finger tight, i.e., "snug".

Now, once the safety plug is in, you will get full pack voltage at those two locations.

LPC-150-350 power supply will charge 350mA. 3-4 hours should be enough to get your pack to a state that is safe to start the ICE. For a battery that is very low, I wouldn't be concerned about as much as 12 hours of charging provided you're checking it for warmth every 30 minutes or so after the 8 hour mark. This is extremely conservative. I put in quite a bit more than that at higher currents and never felt any heat at all. To protect the power supply from the battery, you should install 2X 1N4005G diodes in the output lines. The positive lead should have the diode stripe on the battery side of the connection, and the negative lad should have the diode strip on the power supply side of the connection.

When finished charging, remove the safety plug and fully reconnect the main relay and ECU. The two 8mm bolts connecting to the main plug should be 48 in-lb. The 10mm orange terminal bolts need to be a little tighter. I just used 48 in-lb and went a little further.

You can start it with the cover off provided all electrical connections are tight.
 

Last edited by S Keith; 12-04-2017 at 08:28 PM.
  #2  
Old 04-13-2019, 09:31 PM
Enthusiast
Join Date: Apr 2019
Posts: 4
Default Re: HV Battery Jump

I'm wanting to charge my 09 FEH hv battery, but confused on something. The LPC-150-350 states 200-240ac input and has only two leads. So I need a AC programmable power supply to use this or you using just 110v to power this?
 

Last edited by twinduct; 04-13-2019 at 09:44 PM.
  #3  
Old 04-13-2019, 10:00 PM
Ridiculously Active Enthusiast
Thread Starter
Join Date: Sep 2014
Location: Mesa, AZ
Posts: 2,921
Default Re: HV Battery Jump

For 110V use LPC-100-350 and APC-35-350 with outputs wired in series.
 
  #4  
Old Today, 11:10 AM
Enthusiast
Join Date: Apr 2019
Posts: 4
Default Re: HV Battery Jump

What current input would you recommend if one had a capable charger and for how long? Without cooling the hv battery, but monitored of course.
 

Last edited by twinduct; Today at 01:43 PM.
  #5  
Old Today, 11:18 AM
Ridiculously Active Enthusiast
Thread Starter
Join Date: Sep 2014
Location: Mesa, AZ
Posts: 2,921
Default Re: HV Battery Jump

Assuming:
1) HV battery is at least 80% new capacity
2) HV battery is at 0% SoC.

Highest current possible up to 3000mAh input. Above 3000mAh input, provide some means of cooling at any current. If you can monitor it, you can cool it.

If SoC is unknown, charge at 0.5A max with cooling.
 
  #6  
Old Today, 11:30 AM
Enthusiast
Join Date: Apr 2019
Posts: 4
Default Re: HV Battery Jump

Easy way to find it's SoC with hv battery out of the car already? I would assume that would entail probing a stick to figure this out.
 

Last edited by twinduct; Today at 11:42 AM.
  #7  
Old Today, 12:38 PM
Ridiculously Active Enthusiast
Thread Starter
Join Date: Sep 2014
Location: Mesa, AZ
Posts: 2,921
Default Re: HV Battery Jump

Not really. NiMH resting voltage is completely unusable as an SoC estimation UNLESS it's less than 1.2V/cell. Then you know it's dead, so < 300V on a FEH is at 0% SoC.

If your battery starts the car, then it probably doesn't need charging.
 
  #8  
Old Today, 12:41 PM
Enthusiast
Join Date: Apr 2019
Posts: 4
Default Re: HV Battery Jump

Thank you very much.
 
  #9  
Old Today, 01:03 PM
Enthusiast
Join Date: Mar 2015
Posts: 2
Default Re: HV Battery Jump

Originally Posted by S Keith View Post
Not really. NiMH resting voltage is completely unusable as an SoC estimation UNLESS it's less than 1.2V/cell. Then you know it's dead, so < 300V on a FEH is at 0% SoC.

If your battery starts the car, then it probably doesn't need charging.
So how do you determine the "health" of an old battery (say 10+ years ) that outwardly is not showing any signs of problems:
  • No error codes from vehicle
  • Battery maintains voltage when parked unused for weeks
  • Battery starts ICE quickly and easily
Thanks
 
  #10  
Old Today, 02:06 PM
Ridiculously Active Enthusiast
Join Date: Mar 2006
Location: Ventura, CA
Posts: 878
Default Re: HV Battery Jump

Originally Posted by Automate View Post
So how do you determine the "health" of an old battery (say 10+ years ) that outwardly is not showing any signs of problems:
  • No error codes from vehicle
  • Battery maintains voltage when parked unused for weeks
  • Battery starts ICE quickly and easily
Thanks
I'm interested in knowing this too.
Is there a definitive test for HV battery health that can be performed without opening the battery?
 
Related Topics
Thread
Topic Starter
Forum
Replies
Last Post
pakirk
Saturn Vue Green Line
2
09-26-2013 07:14 AM
Jan in California
Ford Escape Hybrid
1
08-17-2013 07:16 PM
ukrkoz
Toyota Camry Hybrid
0
07-15-2012 10:05 AM
LeeS
Honda Civic Hybrid
1
09-01-2011 03:44 AM
photon87
HCH II-Specific Discussions
4
07-01-2009 04:33 AM


Thread Tools
Search this Thread
Quick Reply: HV Battery Jump


Contact Us - Archive - Advertising - Cookie Policy - Privacy Statement - Terms of Service

© 2019 MH Sub I, LLC dba Internet Brands

We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.