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Traction Battery, from beginning to end

Discussion in 'Gen 2 Prius Main Forum' started by DoIt, Nov 21, 2021.

  1. DoIt

    DoIt Junior Member

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    Albert, it appears that you have 4 bulbs in series. I am assuming that they are 60v bulbs, yielding 240V. While I'm awaiting the HLG-80H-C350A and module, I'm building similar. Thanks.
     
  2. Albert Barbuto

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    The bulbs are 2 in series. This allows me to precisely set any load I desire. Also, I had on hand many 75w bulbs, so 4 bulbs gives a good load when starting the discharge.
     
  3. Another

    Another Senior Member

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    I always wondered why I was keeping a box of old incandescent light bulbs in the attic after swapping them out for LEDs years ago.
     
  4. DoIt

    DoIt Junior Member

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    Yeh, I've only found 2 40W bulbs so far at home and Walmart was void of incandescent bulbs. We may need explore other methods and am thinking a hot plate in parallel with the 2 40W bulbs (series) might work.
     
    #24 DoIt, Nov 30, 2021
    Last edited: Nov 30, 2021
  5. DoIt

    DoIt Junior Member

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    Thanks for the posts all. I've boiled down a step by step for under $100. Hopefully, this gives me at least a 75% probability of success. I haven't started step 6 yet, so yeh, I haven't done much of anything for the fix.

    1 Dr. Pruis Scan $15
    2 order replacement module $21
    3 order charger, HLG-80H-C350A $50
    4 make bulb discharger $5
    5 schedule 1 wk down time of car
    6 remove battery pack
    7 read initial voltage of pack
    8 remove bus bars and soak copper in vinegar
    9 read initial voltage of each module
    10 replace low voltage/bad module
    11 exchange placement of modules 1-14 with 15-28, moving mid modules toward ends, and replace bus bars
    12 charge pack overnight to about 235-240V, while fanning
    13 discharge to about 134V, while fanning
    14 repeat 12 and 13, discharging to about 101V
    15 repeat 12 and 13, discharging to about 84V
    16 repeat 15, up to 3 times, finishing with a charge
    17 replace pack, Dr Prius scan, pray
     
    #25 DoIt, Dec 2, 2021
    Last edited: Dec 2, 2021
  6. nancytheprius

    nancytheprius Active Member

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    my guess is you’ll want a couple replacement modules…
     
  7. 2010moneypit?

    2010moneypit? Active Member

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    Make sure you add a step to run the fan for cooling while charging and discharging the pack. Otherwise you will damage it.
    Good luck!! Hope it works out.
     
    nancytheprius likes this.
  8. DoIt

    DoIt Junior Member

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    thanks, revised
     
  9. AlexY

    AlexY Member

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    Replacing with genuine and new battery will give a car another 10 years of life, if it is in physical condition to last another 10 years it is best option.
    I did this 4 times in 2001 prius every about 6 months, once in 2006 over a year ago, both were under 160000 miles, your battery is 250000 miles, Dr Prius app show 23, 24 mOhm resistance where usually it is 20, consider this battery to be dead, it is gambling when next cell will fail. Also all job with removal, moving heavy battery with sharp edges... better to do it once and forget about it for 10 years.
     
    Hanging on with 286k and ammdb like this.