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Want to rebuild my traction battery

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Mountweasel64, Jun 29, 2023.

  1. Mountweasel64

    Mountweasel64 Junior Member

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    So I recently bought a pair of gen2 Priuses, one for each daughter. Both apparently have bad batteries, but I already have a wrecked gen 2 with a 2 yr old rebuilt battery that seems really good. So, I put the rebuilt battery from the wrecked gen 2 into Prius #1, and got it back on the road. Now I have 2 bad batteries that I’d like to combine into one good one and put into Prius #2. If it works, I’ll have two running Priuses without having to buy a battery. Battery out of Prius #1 has 5 cells with extremely low voltage, 2-3 volts. Obviously bad. What’s the best way to test/recondition the cells to have the best chance of building a good battery? I’ve watched a lot of videos on using hobby chargers to cycle the batteries to recondition them, but everyone has a different idea/method to do it. Btw, I’m an electrical engineer and have worked on industrial vfd inverters for 30+ years, so I’m capable of working on a Prius without killing myself. Also a pretty good diy mechanic, have rebuilt and swapped out engines etc. Anyone who can point me in the right direction would be greatly appreciated.
     
  2. BiomedO1

    BiomedO1 Senior Member

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    Do a proper load test on each individual cell before placing it into your rebuild #2 pack. Get all batteries to the same level prior to assembly - this reduces the balancing load to the on-board pack CPU.

    Good Luck....
     
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  3. dolj

    dolj Senior Member

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    It's modules, not cells. Due to the sealed nature of the battery modules, it is not possible to do any cell-level work.
    In addition to this it would be advisable the do a charge/discharge balancing regimen on each module (or on the pack as a whole if you have a grid charger) to ensure you have the best possible chance of success.
     
    #3 dolj, Jul 1, 2023
    Last edited: Jul 1, 2023
  4. BiomedO1

    BiomedO1 Senior Member

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    Relax Dolj; simply using the same terminology as the OP; so as not to confuse matters. I'm pretty sure no-one here is stupid enough to cut open a battery and deal with the caustic sludge within.....o_O(n)

    Then again; I'm not afraid to admit when I'm wrong. :barefoot:
     
  5. Mountweasel64

    Mountweasel64 Junior Member

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    Thanks to both of you for the replies. I know each module consists of two cells, I’ll try to use the correct terminology going forward to avoid confusion.
    I Just had a long day swapping inverter cooling pumps around until I finally found one good one out of the three Prius’s I own. So, I didn’t have time to look at the traction battery modules, But I got Prius A (Alexis) going with the use of the inverter pump from Prius B (Brittany) after the aftermarket one in Prius P didn't work.
    I need to do a quick combination of good cells to get Prius B going. Should I just look for highest volrage/closest balance?
     
  6. donbright

    donbright Active Member

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    each module consists of 6 cells. each cell is 1.2 v. each module is 7.2v, there are 28 modules. you cannot tell if a module is "good" without putting it through a charge/discharge cycle, so there is no quick way.
     
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  7. Brian1954

    Brian1954 Senior Member

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    ^+1... Also, to add to what you already wrote, 2 modules make up a block. So there are 14 blocks in the HV battery. You can use apps like Dr. Prius, Torque, etc. and Techstream, and other OBD2 scantools to look at the 14 block voltages in the HV battery.

    Posted via the PriusChat mobile app.
     
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  8. Mountweasel64

    Mountweasel64 Junior Member

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    Ok, let’s try this one more time. I have one bad battery that I have already disassembled down to the module level, and checked the voltage on each module. Most of the modules show what you’d expect, somewhere around 7.2 V, but a few are much lower, about 1.5 - 4 VDC. These modules are obviously bad.

    Short term: I have a second bad battery pack that I want to disassemble and use to replace the obviously bad modules on the first battery. I don’t yet have the time or equipment to do charge/discharge and load test on them, so I want to find the 28 best modules out of the 56 I have with the test equipment that I have on hand to give me the best chance of success.

    Long term: test/recondition all of my modules with the goal of having a good battery in each Prius and a spare battery for when one of my mine start giving trouble. This probably means buying a hobby charger and possibly a grid charger.

    1. what’s the best way to achieve my short-term goal and get the Prius with the bad battery back on the road?
    2. What’s the best bang for the buck hobby charger and do I need a grid charger to really evaluate/repair the modules?
     
  9. dolj

    dolj Senior Member

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    There is no really good way for this option, even using static voltage measurements you will come up short. Guess which modules are good and whack them in, then hope for the best.
    There are advantages and disadvantages to using module chargers and grid chargers. My personal preference is a grid charger because it is the quickest method to do the charging

    You will also need a halogen headlamp load tester to load test each individual module and a discharger (able to handle 250 VDC) to do the discharging of the whole battery.

    YMMV.
     
  10. mr_guy_mann

    mr_guy_mann Senior Member

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    1) There are many many posts about DIY module replacement. Overall you have an extremely low chance of swapping modules around and having it work. Playing the lottery has better odds. (All you need is a module and a dream?..)

    So the "best" way to get a working pack is to buy one, be it new from Toyota or a complete set from a wrecking yard.

    2)Do research on what you want to do. I did my pack using hobby chargers. At the time all of the popular 4 channel chargers were not available. I had 5 or 6 single units - you want something that can discharge at 10W minimum. Each module needed 4-6 cycles at 5-6 hours per cycle. It took over a month.

    Grid charging takes the least time.

    Posted via the PriusChat mobile app.
     
  11. Mountweasel64

    Mountweasel64 Junior Member

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    Ok, sounds like a grid charger is the way to go. I’ve never bought one, so is there a particular model that is recommended? Pretty sure I can rig up a halogen headlight load tester. Sounds like it may be some trial and error to find 28 serviceable modules. Would it improve my odds to load test the modules without first charging them? I’m thinking put a headlight load tester on each module for 2 minutes and record beginning voltage and ending voltage for each module. Then select the modules with the least amount of voltage loss during the test. Or maybe just the ones with the highest ending voltage. Would that be feasible?
    Also think I need an elm-type interface to connect to Dr Prius and Torque app. Any suggestions on that?
     
  12. bisco

    bisco cookie crumbler

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    prolong from hybrid automotive is the only one i have read about, but there are others