Gen II Prius Individual Battery Module Replacement

You are welcome. I had typos in steps 12 and 14. Corrected.

 

Just a little clarification of what Steve is talking about. After discharging to 6 volts module voltage will bounce back to 7.2 + volts. Good modules will hold this bounce back almost indefinitely. Modules that drop below 7.2 volts are junk.

 

Actually, I meant the check to be before the discharges. I edited the steps to put the voltage check before the discharges.

I'm assuming the seller has only checked the as-removed voltage.

 

I jumped in somewhere in the middle of the edits. The steps look good now except for #1. I am missing the point of charging module # 28 to nearly full. Another nit picking item is modules 1 and 14 capacities are measured before a deep discharge and the new module capacities are measured after the deep discharge.

Steve's concept is to deep discharge the whole pack with light bulbs to eliminate voltage depression. This is in place of taking weeks to cycle each module individually. The two new module capacities are compared to just two of the old modules. Again this is to save time due to the lack of several high rate dischargers. It will work fine for DIY if your ok with redoing again sometime.

Brad

 

Bah... This is what I get for rushing through something. I'm pretty sure I've spent more time editing/correcting than I would have if I had slowed down for the initial post.

 

I am not in a big rush to get it back together. I want to keep the car for a long while, maybe I will order the Reaktor charger. Was unclear on qty (1 or 2) Reaktor chargers/deep cycle batteries/12 volt chargers that was suggested ?

CJ

 

Only the last two modules discharged require a full charge. The others are already partially charged. The downside to this is the workspace is very tight and you need to be really careful what metal touches what other metal.

 

Ok. Just ordered the two Reaktor chargers from HK. Any advice on the settings, I guess it should be different from the B6 ? I will do the discharge with the lights first.

CJ

 

Yes. Make sure you recharge the module you discharged before you do the light bulb discharge. It is already depleted, and it is a good idea to get some charge back into it before you discharge it again.

 

Wow! Chargers should be here before the weekend, I'll let you know how it goes. Thank you again!

CJ

 

Started the 2 x 25w light bulb in series drain. Know approx how long it takes to get down to 85v ?

 

You recharged the one module you discharged, right?

 

Yes I did charge #28 first. I thought the other post said to go down to 85v? So 185v is the discharge level? It took 2 hrs to go from 215v to 205v so far.

Thank you
CJ

 

Was on mobile.

 

Oh ok. It took a while to get down to around 120v but is dropping faster down to 85v. Is that correct or should it be an continuous rate?

CJ

 

For a given bulb, even with the tapering current, it generally accelerates.

 

I did get the two Reaktors. It's now down to 85v, going to swap the 2 cells in now. I'm not in a hurry but curious how long the charge cycles take using two Reaktors, also is there still discharge cycles?

Thanks
CJ

 

Also...merged. never ever ever accidentally touch the test leads to the same battery that's powering the Reaktors.

Don't ask me how I know.

 

Bet the Reaktor did not like that! So I'm discharging the 2 new modules. While waiting I checked the voltage on the others in the pack to see what they are after being taken down to 85v. They range from 4.69v to 7.1 most are 5 to 6. Should they be so dissimilar?

CJ

 

This is not the death sentence one is accustomed to when inspecting voltage on modules fresh out of the car. Those modules likely had cells reversed at car currents (20A+).