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got some young 2012 modules

Discussion in 'Generation 1 Prius Discussion' started by scotman27, Apr 10, 2014.

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  1. scotman27

    scotman27 Active Member

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    Yes, they seem to be identical. I got my parts to make the pack a gen 1 pack so I can do my testing while it's out of the car. I.can't remove the battery out of the car because I need it., possibly next week my tests will show a very good pack and ill be putting it In the car.
     
    #61 scotman27, Apr 14, 2014
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  2. bwilson4web

    bwilson4web BMW i3 and Model 3

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    If you still have the crappy, old modules first replaced, you might put them with a new one and using a telephoto setting, take a picture of the two, side-by-side. This can help folks see how similar they are.

    Bob Wilson
     
    #62 bwilson4web, Apr 14, 2014
  3. scotman27

    scotman27 Active Member

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    Ill see if I can do that and post it here. hopefully the tests reveal that all modules i received are good then next week i can replace my old ones on day off next wednesday and ill take the pictures then. if i didnt need the car i would pull my old pack out,
     
    #63 scotman27, Apr 15, 2014
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  4. scotman27

    scotman27 Active Member

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    got my resistors yesterday early. i just ran over them with my meter. lowest ohms is 70.3 ohms highest 70.5 ohms. i think that will do pretty good. right now im parallel charging the pack in the garage before work and then ill pull it out of parallel and see what happens when im at work with the voltages. or should i leave it in parallel until i come home from work then pull it out of parallel and let it sit for a couple hours while i get the resistors ready for testing tomorrow? i leave for work at 11: 30 ish today
     
    #64 scotman27, Apr 15, 2014
  5. bwilson4web

    bwilson4web BMW i3 and Model 3

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    Gosh I hope your charger stops at a set voltage no higher than 8.0 or 8.1.

    Bob Wilson
     
    #65 bwilson4web, Apr 15, 2014
  6. scotman27

    scotman27 Active Member

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    at 1120 the charger shut itself off at 8.1 volts. I left the pack in parallel and disconnected and unplugged the charger. the voltage was at 8.10 v.
    I get done at 9 o'clock tonight what I will do is I will check the voltage when I get home and I guess take the pack out of parallel so when I sleep tonight I can check the voltage of each individual module in the morning to see if there is a voltage difference.
     
    #66 scotman27, Apr 15, 2014
  7. scotman27

    scotman27 Active Member

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    with good modules what do you think the voltage drop should be in parallel?
    also with good modules out of parallel what should the voltage drop be?
     
    #67 scotman27, Apr 15, 2014
  8. scotman27

    scotman27 Active Member

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    also does it matter what polarity the resistors are in when I connect them to the modules?
     
    #68 scotman27, Apr 15, 2014
  9. bwilson4web

    bwilson4web BMW i3 and Model 3

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    Once the parallel charge is done, isolate the modules so a 'stronger' one won't 'help' a weaker one. Also, resistors are unidirectional. You're good to go.

    Were you able to extract the spreadsheet?

    Worse comes to worse, I could put it up on Google.

    Bob Wilson
     
    #69 bwilson4web, Apr 15, 2014
  10. scotman27

    scotman27 Active Member

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    Yes I was able to extract the spreadsheet. unfortunately I am at work until 9 and I left the pack in parallel. should I go back home tonight and just take it out of parallel for the night and see what happens in the morning or should I get home tonight recharge the pack in parallel and then when the charger kicks off take the pack out of parallel and let it sit and see what the voltages are in the morning?
     
    #70 scotman27, Apr 15, 2014
  11. scotman27

    scotman27 Active Member

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    Yes I was able to extract the spreadsheet. unfortunately I am at work until 9 and I left the pack in parallel. should I go back home tonight and just take it out of parallel for the night and see what happens in the morning or should I get home tonight recharge the pack in parallel and then when the charger kicks off take the pack out of parallel and let it sit and see what the voltages are in the morning?
     
    #71 scotman27, Apr 15, 2014
  12. bwilson4web

    bwilson4web BMW i3 and Model 3

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    In parallel mode, a weak module will vampire charge from a strong module. If you've got resistors to make, yes, go ahead and get them all charged to 8V and then let them rest as you isolate them but there is no fixed 'rest period' to follow.

    As they rest, there will be some 'self discharge'. It is NOT a primary determinant because we don't know if the self-discharge is internal or external (i.e., stuff on the outside of the case conducting between the terminals versus internal electrolyte.) I don't pay it much mind except as 'Oh, that one sinks a little more.' Really a 'rest' is chance for any gasses and heat generated during the charge to recombine(*).

    The real test is when the resistors all go on and start putting a load on the modules. Then start the 9-10 hr clock; spot check after an hour or so and take a nap. Did I mention the resistors will get HOT! HOT means you can't pinch them because your fingers are about to blister. Warm, you can touch but don't feel it is cooking your skin and this is OK.

    Don't let these HOT resistors rest against the module, thermal plastic case as you don't want to melt them. You also don't want resistors too close to the terminals as they are also heat sensitive. I don't have any standard references handy but try to make sure there is an air-gap around the resistors. Aluminum foil can be your friend IF you don't make the foil into a short around the resistor. Hummm, wooden chopsticks might serve as quick platforms to keep the resistors above the modules.

    Bob Wilson

    (*) - Someone has probably written a paper on NiMH 'rest' periods but I don't know of any.
     
    #72 bwilson4web, Apr 15, 2014
  13. scotman27

    scotman27 Active Member

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    Ok so let me get this right, when I get home check voltage in parallel. then recharge til charger shuts off while making resistors, record voltage. Take pack out of parallel and keep making resistors. In the morning or after a couple hours check voltages of each module
     
    #73 scotman27, Apr 15, 2014
  14. scotman27

    scotman27 Active Member

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    ok When I left for work yesterday the charger had stopped charging and the pack was in parallel it was at 8.10v. I left it in parallel and when I came home last night the pack was sitting at 8.02v after 9 hours of sitting. my old pack would drop down into 7.8 in that amount of time.
    so i recharged it, charger stopped at 8.18v i left it sit parallel for about 30 mins and pulled it out of parallel, individual voltages were at 8.16v. i know my old pack would start to see voltage differences almost right away.
    i just checked individual voltages and they are at8.14v to 8.13v ten of them are either steady or bouncing back and forth from 8.14-8.13v the rest are a steady 8.13v. this is after 7 hours of sitting. i take that as a good thing. now to get the resistors hooked up. i know my old pack was kind of all over the place voltage wise.
     
    #74 scotman27, Apr 16, 2014
  15. scotman27

    scotman27 Active Member

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    Bob:
    is your spreadsheet going to allow me to start the resistor test at 8.13v?
     
    #75 scotman27, Apr 16, 2014
  16. scotman27

    scotman27 Active Member

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    nevermind, i see that it will allow me to do that, i just changed the ohm values to 70 ohms. now as for the resistors, the leads on the resistors are 2" long can I connect to resistor directly to each module, than run wire to the other side of the module? that would allow me to keep the resistor off the module, keep it organized, and i could put 2 fans to blow across the battery to keep it cool without having to worry about the resistors being blown into one another. would that work ok or will it get hot enough to melt the terminal?

    thank you
     
    #76 scotman27, Apr 16, 2014
  17. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    Your doing great. Just keep the resistors from burning the modules (or anything else you don't want them to burn).
     
    #77 usnavystgc, Apr 16, 2014
  18. scotman27

    scotman27 Active Member

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    so im ok to connect one of the leads directly to the terminal without burning up the terminal? the resistor would be about 1 1/2 to 1 3/4 inches away from the terminal
     
    #78 scotman27, Apr 16, 2014
  19. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    Oh yeah, its ok as long as the resistor body is not touching any plastic part of the module.
     
    #79 usnavystgc, Apr 16, 2014
  20. scotman27

    scotman27 Active Member

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    ok at 12:15 i began connecting the resistors. starting voltage is between 8.13 to 8.12 ten minutes later i checked the voltages they are at 8.09v. seems rather quick that they would drop like that. is that ok or is that because the voltage was topped off?
     
    #80 scotman27, Apr 16, 2014
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