I sold my Gen1 to a friend and although she is very happy with it, is concerned about the 11yr/282k miles on the traction battery. I had these same concerns myself intially but felt the replacement, when required, would be a something I could do with an upgrade to the Gen2 battery pack. I want to be able to support this change out if it should become necesssary in the future and have a couple Gen2 batteries in my collection of spare stuff. I don't think I would want to sacrifice both to build this battery but see that individual cells sell for around $45 on ebay. However, if I count correctly, the Gen1 needs 38 cells and the Gene2 pack only has 28 so I would be adding 10 additional of the newer cells. Is that correct?? Or is there a difference in the voltage in each cell and I would add additional cells to achieve the nomial Gen1 pack voltage. Then, how will all of these Gen2 cells fit into the Gen1 case and harness/hookup to the BMS and other components. I don't really need to do this now, but want to have an understanding of what is involved in the even my freind "gives me that call for assistance". Steve
you can try this: http://item.mobileweb.ebay.com/viewitem?itemId=261195757985&index=0&nav=SEARCH&nid=62177669159 Or this: http://item.mobileweb.ebay.com/viewitem?itemId=261196500959&index=3&nav=SEARCH&nid=23169111870
Thanks, Looks interesting. Never paid for a YouTube video before, but eventually everything on the internet seems to come at a cost. Excuse the Rant, but you can't even look up a phone number anymore without paying or subscribing to some service and if you do find one for free, they want you to pay for the address. Humm! I think my cell phone allows me to call 411 so many times for free. Back On Topic: I contacted this fellow to ask specifically if he deals with the question/problem of fitting 38 Gen2 modules into the Gen1 case and if the bus bars, BMS and other stuff "all get along" with out complications?? Haven't heard back yet. Also curious, but didn't ask if these videos deal with the balance charging of the modules prior to assembly or if that all comes afterwards? Or do you just charge each module to the same voltage before assembly? I guess charging after assembly would be problematic due to the high voltage unless it were done throught the Prius BMS from the ICE system. Sorry, just thinking out loud! Steve
There are many threads on PC that deal with rebuilding HV batteries and some of them are specific to the Gen1. Yes. Gen2 or the somewhat better Gen3 modules can be fitted into a Gen1 pack. Yo do need 38 plus a few spares and there are only 28 in one of the newer HV batteries. It is best if you first rebalance all of the modules to equalize the charge on the 6 NiMh cells in series within a module and then match up 36 modules with the same amp-hour capacity, internal resistance and state of charge (SOC - same terminal voltage). search for and read the threads, then ask questions. JeffD
The key to using gen2 modules is getting all 38 to be very similar with respect to capacity and internal resistance. If modules vary too much, the car will code and you get to play whack a mole. Since you need more than 1 Gen2 battery pack to make a Gen1 battery, this can be tough. Gen2 modules are slightly larger than gen1, but they will fit in the battery enclosure with slight persuasion.
Well, I do not recommend doing this,but yes you can put gen 2 modules in a gen 1 case. Let me clarify a little bit,I do not have a problem putting gen 2 modules in the gen 1 case. However what i do not recommend is mixing 1st and 2nd gen modules in the same pack. It can be done,as I have done it to my project /work car. The 2nd gen have only one bolt hole in the bottom where the 1st gen have 2,but they still bolt in. You have to grind off the little NIPPLES on the 2nd gen modules so they will fit up against the 1st gen. the copper buss bars will also work ,but the 2nd gen module is about an 8th inch longer so you have to be careful when you put on the copper buss bars. AGAIN I DO NOT RECOMMEND THIS AT ALL,but to let you know it can be done..
I would never mix gen1 and gen2 modules in the same battery enclosure, their characteristics are different and the car will most likely code after a short while. It is not all that difficult to build gen2 cells into a gen1 enclosure, re-involt, ourselves, and many others routinely do it. The Gen2 modules are slightly larger and a bit trickier to install, but will work better than Gen1 modules.
The same statement, but not as critical, can be made about mixing Gen2 and Gen3 modules due to the lower internal resistance of the Gen3 modules. JeffD
I agree with you Paul,just for information's sake I put about 10 gen 2 modules in the middle of my gen 1 battery and I have put about a total of 30k miles on it like that and still have not had a problem with the car or check engine light .. Its been about a year ago now so I do not know how much longer it will go??? It may be another year or 2 or it could be a week who knows..On the good side I still get in the mid 40s for MPG
It is good to hear that mixing Gen2 and Gen1 modules worked in your battery, I personally would never do it and I am surprised that it has worked so long without coding. Hopefully it will stay working. You must have lucked out finding Gen2 modules with very similar characteristics to your Gen1 modules. Others attempting to copy your technique should be aware that YMMV.
