Gen II Prius Individual Battery Module Replacement

excellent result

 

regardless of which way we do this, its only a band-aid anyway.... if you want to get this "right" go to the bank get out about $3K and go buy a new battery! drive car for 10 more years....

Counting capacity with hobby chargers and matching pairs works great! its by far the most convenient and efficient way for backyarders to bodge up a pack! some people have luck just slapping a module in the car and driving, other people "go on" about needing thousands of dollars worth of complex expensive garbage but all for what? to test some ten year old batteries that ultimately should be replaced with brand new parts because their near at the end of their consumable life anyway....

 

Kiwi,
You have miss read Steve's graph. There are three lines plotted. They all share time along the bottom. On the far left is current. The top horizontal red line plots amps vs time. The current draw was a consistent 20 amps throughout the test. The near right is voltage. The blue line plots module voltage vs time. This is a typical graph of a good module with 4800 mAh capacity. The far right measures capacity. The brown line plots capacity vs time.

Brad

 

See Brad's post.

There are no errors in the capture. There was no change in load except at the termination of the test.

They are very easy to compare. I can overlay them within the same data file.

Test was done under constant electronic load of 20A. Characteristics of modules at 20A are very different than at 6A. 6A is nothing in the car. 20A is actually very light acceleration or full electronic load with A/C on full.

You're missing a big part of the picture here. There's no set threshold. There is a threshold for a given current. At 20A there is value. The range you have set is for 6A, and I would tend to agree. 6A isn't much of a load. I think if you had interpreted the graph correctly, you wouldn't have said the above. I'm looking at Techstream data that says 13.44V on block 6 at 47.5% SoC.

 

I can rebuild a battery with brand new cells for $2,500. Most people don't have the time or even a garage to work in; they just want to drive it.

Joke: How do you drive an engineer completely insane?

 

I know! Pair them with a scientist like me!

 

lol...or somebody like me! Answer: Tie them to a chair, stand in front of them and fold a map the wrong way. I do appreciate them though for sure.

 

ohh yea, I guess you mean new modules! .. may I ask, where do you get them from

 

I import them from Japan.

 

How much would you charge for these modules to one of us DIYers?

JeffD

 

non genuine ?

 

module number, serial number (all started with 27XHEA), open circuit voltage. #11 is the only one (at the moment) that looks verklempt.
1 03307Y 7.97
2 03278Y 8.06
3 03274Y 8.05
4 03302Y 8.06
5 03303Y 8.05
6 03374Y 8.04
7 03305Y 8.06
8 03306Y 8.05
9 03263Y 8.04
10 03264Y 8.05
11 03261Y 6.75
12 03262Y 8.04
13 03256Y 8.04
14 03238Y 8.05
15 03241Y 8.05
16 03239Y 8.06
17 03265Y 8.05
18 03267Y 8.05
19 03252Y 8.04
20 03253Y 8.05
21 03254Y 8.07
22 03255Y 8.05
23 03257Y 8.05
24 03249Y 8.06
25 03260Y 8.08
26 03248Y 8.05
27 03520Y 8.06
28 03251Y 7.95

 

Yup 11 looks nasty! October 2006 according to the identification table

 

I've mentioned in the past that non-OEM modules are available for purchase.
Anyone can buy them. Or sell them to others.
Heck I can drop ship you some today. How many you want, 28? 56? 280? 560?
Call me and we can discuss.

The biggest issue with the aftermarket modules is that you will not have a warranty.
Well, I take that back, you will have a warranty. It's just that you'll have to work with Asian suppliers to activate it. It an be expensive sending your failed modules back to Asia. Or convincing Asian suppliers to agree that the module failure was the part's fault, and not user error. Often they will simply credit the failed module toward your next module purchase.

 

Not if you use kiwi's Battery Analyser!!!!

 

Would you trust them? never seem to have much luck with cheap copies of really anything!

ohh yes the 20channel 6A AnaL-yser been meaning to grab a couple

 

No.

 

I put some on Ebay if I have extras. But I'm not sure I think it's a good idea to promote diyers working on these batteries; they can be very dangerous! This is an example of what can happen with one simple mistake! Please be very cautious people!

 

That video doesn't show what was done wrong... Almost like its sole purpose is to scare people

SAMSUNG-SM-N900A ?

 

Finally got the pack back together. Man, what a pain! Had to remove the electronics from end of the pack and use some pipe clamps to hold them together.

I'm doing the final voltage balance using the 55w halogen bulb. Is 7.75 a suitable voltage for the individual modules, or do I need to get them lower than that?