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Yet another battery rebuild...

Discussion in 'Gen 2 Prius Main Forum' started by zuluhotel, Sep 20, 2016.

  1. zuluhotel

    zuluhotel Junior Member

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    Hey everyone,
    First time posting! I really like the forum here and the contributions by everyone have helped me much of the way on getting my prius going.

    So long story short, I bought a full battery core off eBay that was supposedly working when it was taken out of the car. I have it open right now and have taken voltage measurements from each module today before making an modifications and here's what I've found.

    Voltage as of 09/20/2016

    01. 7.32v
    02. 7.41v
    03. 7.41v
    04. 7.41v
    05. 7.41v
    06. 7.41v
    07. 7.40v
    08. 7.40v
    09. 7.40v
    10. 7.40v
    11. 7.40v
    12. 6.24v
    13. 7.40v
    14. 7.40v
    15. 7.40v
    16. 7.41v
    17. 7.40v
    18. 7.40v
    19. 7.40v
    20. 7.41v
    21. 7.40v
    22. 7.41v
    23. 7.41v
    24. 7.41v
    25. 7.41v
    26. 7.42v
    27. 7.42v
    28. 7.31v

    From what I've read here, I think I have a good pack to use and the car supposedly had 104,000 miles on it so I'm excited about this pack working out for me.

    I've got the two end modules -and what I perceive as as the bad module (12)- cycling right now on a B6AC v2 to see what capacities they might achieve with a little love. Should I just scrap 12? Are the end modules 1 and 28 bad as well? I have some known good modules sitting around to use if I need. Andvice right off the bat? I don't want to cycle the other packs and feel better leaving the. Where they are. Is this a good idea? Thanks for any help you might be able to give me on this.

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    #1 zuluhotel, Sep 20, 2016
  2. dolj

    dolj Senior Member

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    No. 12 is toast, just throw it away, or use it for experiments. Otherwise that pack looks in good shape.

    You need to replace it with a module that has the same capacity as the others, otherwise you're just wasting your time.

    I'd at least charge each module to 8.4 V @ 345 mA (no more) with it clamped and with cooling, and continue the charge for a further 4-6 hours to balance the module.

    To work out the capacity you will need to do at least one discharge cycle, which will mean you will then need to do a full charge again.

    The end modules are typical of the end modules, but no-one has explained why, so far that I have read.

    Let us know how you get on.
     
    #2 dolj, Sep 21, 2016
  3. JC91006

    JC91006 Senior Member

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    What's the first 4 digits of the serial number on the modules? If the pack is old, you will want to discharge and recover some lost capacity

    I'm going to guess this is from a 2005
     
    #3 JC91006, Sep 21, 2016
  4. fotomoto

    fotomoto Senior Member

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    Yeah, ditch #12.

    Interestingly enough, I also lost #12 and later #20 which kinda' bookmarks #12 on the other end. Coinkydink? Well that encouraged me to "shuffle" the whole pack and rotate the outside modules to the inside positions and vice versa when repairing it the second time. Been working great so far at 3 months in but I also grid charge once a month.
     
    #4 fotomoto, Sep 21, 2016
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  5. zuluhotel

    zuluhotel Junior Member

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    To save a bunch of time, I have just replaced #12 with a juicy ebay module and then hooked them all back up in parallel. To do this I took the pack apart and put all the batteries in series/parallel with all - and + on the same sides (not exactly sure what to call it). I am letting the whole pack balance itself and then I will discharge and then charge the pack to balance it.
    Any recommendations on what discharge and charge rates I should use when doing it this way?


    Posted via the PriusChat mobile app.
     

    Attached Files:

    #5 zuluhotel, Sep 24, 2016
  6. zuluhotel

    zuluhotel Junior Member

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    You are correct. It is a 2005. Here's a pic of the serial. 1474765083162.jpg

    Posted via the PriusChat mobile app.
     
    #6 zuluhotel, Sep 24, 2016
  7. dolj

    dolj Senior Member

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    Parallel equalisation.
    Parallel equalisation does not balance the pack and is pretty much a waste of time.

    To balance a module, you need to fully charge it (with cooling and compression) and then continue the charge at no more than 345 mA for 4-6 hours.
     
    #7 dolj, Sep 24, 2016
    PriFi likes this.
  8. zuluhotel

    zuluhotel Junior Member

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    The chargers I have seem to shut off automatically. They are B6AC v2 chargers. And what does "over charge capacity limit" mean. Does anyone know?

    Posted via the PriusChat mobile app.
     
    #8 zuluhotel, Sep 25, 2016
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