1. Attachments are working again! Check out this thread for more details and to report any other bugs.

BULGED BATTERY MODULES? NEVER SEEN THAT BEFORE

Discussion in 'Gen 2 Prius Technical Discussion' started by Dxta, Aug 2, 2017.

  1. Hometown Hybrids

    Hometown Hybrids Junior Member

    Joined:
    Feb 9, 2015
    11
    9
    0
    Location:
    Houston
    Vehicle:
    2005 Prius
    Model:
    Two

    Try using a long clamp that can span the length of the battery :) It is definitely possible to get them back together if only a few are expanded.
     
  2. edthefox5

    edthefox5 Senior Member

    Joined:
    Jul 25, 2007
    10,096
    4,795
    0
    Location:
    Clearwater, Florida
    Vehicle:
    2007 Prius
    Model:
    Two
    You mean span the width of the battery. As far as bolting it back together Its not a length issue is a width issue?

    I think once the battery is distended its done? The case is stressed.
     
  3. khan209

    khan209 New Member

    Joined:
    Mar 4, 2019
    8
    0
    0
    Location:
    california
    Vehicle:
    2005 Prius
    Model:
    Two
    I think its too late to reply but you can get them back. I had the same issue i put the fan on in the cold and cool down them to get them back on the normal condition. they are flexible unless they are way swell
     
  4. Montgomery

    Montgomery Senior Member

    Joined:
    Sep 11, 2015
    2,254
    2,233
    2
    Location:
    Orange County, CA
    Vehicle:
    2015 Prius
    Model:
    Two
    Wow, talk about a hot mess!
     
  5. khan209

    khan209 New Member

    Joined:
    Mar 4, 2019
    8
    0
    0
    Location:
    california
    Vehicle:
    2005 Prius
    Model:
    Two
    Now i got
    P0A9E. Temperature sensor circuit too high
     
  6. ericbecky

    ericbecky Hybrid Battery Hero

    Joined:
    Mar 12, 2004
    4,365
    3,209
    1
    Location:
    Madison, Wisconsin
    Vehicle:
    2005 Prius
    Model:
    Two
    Go back and look at the sensor and wires.
    Make sure they are not damaged.
    Replace as needed.
     
  7. khan209

    khan209 New Member

    Joined:
    Mar 4, 2019
    8
    0
    0
    Location:
    california
    Vehicle:
    2005 Prius
    Model:
    Two
    Thank you Eric, I replaces whole wire harness for temp sensors and its good now. Take care
     
  8. lunacyworks

    lunacyworks Member

    Joined:
    May 13, 2015
    114
    41
    7
    Location:
    SF Bay Area
    Vehicle:
    2008 Prius
    Model:
    II
    I just about had a battery meltdown myself. Had a camera watching the pack and fortunately the expanding pack causes a cable to switch position and trigger motion alert where it drew a square around the motion and I noticed the pack swelling. I was charging at around 4amps which I have been doing fine with, but forgot today was a very warm day in the garage (95F). As I was there I noticed a second pack starting to expand so I was able to disconnect. I have since devised an anti-swell trigger that stops charging at any sign (1mm) expansion while under compression. Fortunately for me both packs return to normal size within 2hrs of cooling.

    Picture: [Pack starting to swell, caught early]

    20190911_132840.jpg
     
    blaisep, R-P and Dxta like this.
  9. katit

    katit New Member

    Joined:
    Jul 25, 2020
    3
    0
    0
    Location:
    St Louis, MO
    Vehicle:
    2007 Prius
    Model:
    Plug-in Base
    Question. I cycle batteries charging at 2Amp. After discharging them to 6V
    Around 5000mAh I get swelling like above. Is it OK? I try to charge up to 7000mAh

    Temperatures of other batteries - 20C, batteires that start expanding around 25-30C

    Should I change something or it's normal? They compress back after cooling..
     
  10. jerrymildred

    jerrymildred Senior Member

    Joined:
    Oct 28, 2016
    11,490
    14,095
    0
    Location:
    Tampa, FL
    Vehicle:
    2017 Prius
    Model:
    Two
    Yikes!!! Two amps for a single module? I've never disassembled a battery to charge individual modules. My charger charges then entire pack at a third of an amp.
     
  11. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

    Joined:
    Feb 14, 2010
    6,035
    3,854
    0
    Location:
    Rocky Mountains
    Vehicle:
    2006 Prius
    Model:
    Three
    No they don't "compress back after cooling". Bulging ONCE makes them garbage. You are putting them in a system where they see 120A currents repeatedly. Bulging means you have broken the internal module goop essentially. There is no knowing if it is all cosmetic (very unlikely) or you have now caused pinhole shorts to open up that when you're cruising down the interstate decide to blow through and start smoking into the cabin.

    2A is fine WITH COMPRESSION. Otherwise stick to under a half amp. Our modules on the other hand have a metal cylindrical shell. No compression required, they are already and always under the mechanical stability they need.
     
    donbright likes this.
  12. katit

    katit New Member

    Joined:
    Jul 25, 2020
    3
    0
    0
    Location:
    St Louis, MO
    Vehicle:
    2007 Prius
    Model:
    Plug-in Base
    What does it mean "WITH COMPRESSION"? I am charging them assembled in a pack. Does it mean compression? I see them bulging but then they return to normal once cooled..
    #3 shows how it is expanding.
     

    Attached Files: