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Bought a gen1, rebuiling HV battery

Discussion in 'Newbie Forum' started by danahurling, May 15, 2014.

  1. danahurling

    danahurling Junior Member

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    New to prii, figured it would be an interesting project. Pulled hv batt and found one suspect cell, so may end up being a cheap fix to get it on the road. Ordered a hitec x4 charger which should be here in a week. Then the fun begins! Heres my inital voltage test results. I see a trend of voltages increasing somewhat as i moved away from the center of the pack. Ill rotate the center cells outward due to this I think. This is starting with cell#1. Cell#15 of course being suspect. Ive seen some other test come out in the 7's, anyone know why my voltages are in the 8's? The pack is out of an 01 with 147kmi. Fresh out of the car.

    8.07
    8.06
    8.05
    8.05
    8.04
    8.04
    8.04
    8.04
    8.03
    8.03
    8.03
    8.02
    8.04
    8.04
    6.72
    8
    8.04
    8.03
    8.04
    8.02
    8.04
    7.99
    8.04
    8.03
    8.02
    8.04
    8.04
    8.03
    8.03
    8.04
    8.05
    8.04
    8.05
    8.05
    8.06
    8.06
    8.07
    8.07 20140513_174208.jpg 20140514_224451.jpg
     
    #1 danahurling, May 15, 2014
  2. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    Yep, clearly you have one bad cell. Voltages at 8.xx are not uncommon. That just means they are holding a good charge (voltage wise). The capacity is the key. Are you gonna cycle all the modules and test for capacity?
     
    #2 usnavystgc, May 15, 2014
  3. danahurling

    danahurling Junior Member

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    Yeah im gonna cycle them all to make sure all the rest are good, load test them, equalize them etc... ill order replacement cells once I determine if any others are just not worth using.
     
    #3 danahurling, May 15, 2014
  4. danahurling

    danahurling Junior Member

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    Any suggestions on the gunk that toyota put on them? Leave it on or clean them all up and put new gunk on?
     
    #4 danahurling, May 15, 2014
  5. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    I'm leaving it.
     
    #5 usnavystgc, May 15, 2014
  6. danahurling

    danahurling Junior Member

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    Yeah sounds like a good plan, looks it would be a big hassle to clean and replace. Thanks for the input, ill post again when I have some more results from the charge cycles.
     
    #6 danahurling, May 15, 2014
  7. scotman27

    scotman27 Active Member

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    i got the same charger, in my thread got some young 2012 modules | PriusChat

    check that out if you want, you'll see how long it can take.
    i believe I posted my setting for the charger in there, so far it works great and the modules responded well.
    if you use those settings, let me know if the bank 2 on your charger detects peak like mine did. I had to drop bank 2 to a 1 amp charge rate. you may be able to revive that one module, i would charge it all the way up, no peak setting, just mah cutoff maybe at 7000, then set it for 3 discharge/charge cycles and see what happens. if that one gets worse, well it was to be replaced anyways. it may however, bounce back.

    Bob wilson however has much more experience with these modules.
     
    #7 scotman27, May 16, 2014
  8. danahurling

    danahurling Junior Member

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    check that out if you want, you'll see how long it can take.
    i believe I posted my setting for the charger in there, so far it works great and the modules responded well.
    if you use those settings, let me know if the bank 2 on your charger detects peak like mine did. I had to drop bank 2 to a 1 amp charge rate. you may be able to revive that one module, i would charge it all the way up, no peak setting, just mah cutoff maybe at 7000, then set it for 3 discharge/charge cycles and see what happens. if that one gets worse, well it was to be replaced anyways. it may however, bounce back.

    Bob wilson however has much more experience with these modules.[/quote]


    Yeah I bought the x4 so at least it wont take as long as using just one like some do. So this charger wont do 5 amps on all 4? I was thinking my cycles would be 5amps to 7300mah then a .7a discharge to 6volts. I picked 7300 because ive seen 7000 as well as 7500. Figured I would play with that bad cell just for the heck of it but likely not use it. Ill check out the other thread thanks!
     
    #8 danahurling, May 16, 2014
  9. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    That 6+V module clearly has a bad cell. It's not even worth your time.

    Nice Gen I btw. I love the white color. White paint holds up so well. Your paint is 13+ years old and look at it shine.
     
    #9 usnavystgc, May 16, 2014
  10. danahurling

    danahurling Junior Member

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    Thanks! Yeah it'll shine up nice. Ill post pics when its done. The wheels are peeling and pitted so im going to pull them and paint them. The headlight housings are sightly yellowed so im gonna fix that as well. But the interior is great. She oughta be a sharp gen 1 when done.
     
    #10 danahurling, May 16, 2014
  11. GregP507

    GregP507 Senior Member

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    I would use the same corrosion inhibitor, if available. The problem with higher DC voltages is that most metals which carry a charge potential which will oxidize eventually with exposure to air and moisture. As we all know, connections on regular car batteries eventually corrode, regardless of what we do. A thick layer of corrosion inhibitor is the best way to delay the process, short of using exotic metals.
     
    #11 GregP507, May 16, 2014
  12. danahurling

    danahurling Junior Member

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    Thanks for the input... my first focus is balancing the cells. Then when I pull the pack apart ill decide whether to mess with it or not. It all appears to be doing its job so ill likely leave it alone.
     
    #12 danahurling, May 16, 2014
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