Gen II Prius Individual Battery Module Replacement

Discussion in 'Gen 2 Prius Technical Discussion' started by ryousideways, Apr 24, 2013.

  1. Cody26

    Cody26 Junior Member

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    Are there some alternatives besides Prolong that does balance the voltages of modules in the pack?
     
    #2221 Cody26, Sep 13, 2018
    Last edited: Sep 13, 2018
  2. Britprius

    Britprius Senior Member

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    You can wire all the modules in parallel and leave them for a few hours, and this will bring them all to the same level.
    The capacity of the modules is automatically measured by the DC6 or equivalent charger.
    John.
     
  3. jdenenberg

    jdenenberg EE Professor

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    1. Make sure that the modules are all close in terminal voltage so that you don't get high currents flowing when you put them in parallel.

    2. It is the total discharge amp - hours that gives the capacity measure. Note that since the small charger - balancers are limited to low current, the reading will be artificially high compared to the specified 1C discharge rate of 6.5 amp - hours.

    JeffD

    Posted via the PriusChat mobile app.
     
  4. Cody26

    Cody26 Junior Member

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    That looks hard to do practically.
     
  5. dolj

    dolj Senior Member

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    It has been established that this "equalisation" process does little and is of dubious benefit. You are better off, just using your load tester to discharge all modules to the same voltage which remain close after they have rested. But really, as long as each module is within 0.3 V, it will be close enough. Bear in mind that each module will also need to remain with that same 0.3 V when being charged or discharged in real life use, as well, so getting them all the close as possible in the first place is a better idea.

    The biggest problem you face is having modules that charge and discharge at different rates, in real life use, and then go outside the 0.3 V differential that the HV battery ECU is looking for. The only way to fix this is to ditch the errant modules and find replacement modules that more closely match the remaining ones.
     
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  6. Britprius

    Britprius Senior Member

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    The current flow really is irrelevant when connecting them in parallel as the voltage difference will or should be minimal, and the modules are capable of withstanding much higher currents in use both in charge or discharge scenarios.

    John.
     
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  7. Skibob

    Skibob Junior Member

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    Are you using the thin wires that came with the charger? I’m new here but I have read the wires that come with the chargers don’t work. You have to make heavy duty ones yourself.
     
  8. dubseven

    dubseven New Member

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    No, I made that mistake the first go around. Made some custom 10ga wires with ring terminals and banana plugs.
     
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