ISO: newpriusbatteries Installation Procedure

Genuinely sorry your car is giving you heartache, not fun having this stuff on your mind

Completely understand why you didn't want to buy another rebuilt pack after all that, it comes down to who does the rebuild and what their standards are like, the pack i built for my daughters car in April 2017 is still in the car today and now has about 100,000km on it, some people actually try to do a decent job of things others are just out to take your money and promise you the world!

I actually believe the data you are getting from the dr.prius app is true enough, I know others have said things like "data from the app is not that great" that just sounds like a cop out to me and i think most people that know, would know!.. the app is reasonably reliable for testing voltage blocks under load and reporting internal resistance, granted it has some bugs but the voltage and ir readings are pretty on point really, the data being reported only comes from the car there is no magic

All BS aside, I think the reason why you are getting low #12 via the app is because you indeed have deteriorated capacity on #12 more than likely from a weak cell/module, when looking at things via the app the pack is under load which is what you want, by the time you pull the pack out and bench test it unloaded a few hours or even days later the modules have enough time for surface voltages to even out but unfortunately having "even" surface voltages unloaded does not necessarily mean they all have even capacity, i hope that makes sense..

Good luck with it

 

Think back to where the safety disconnect is physically attached... Now think to what is being measured... The app doesn't compensate for the safety disconnect switch... Want to try wild guessing again? See why a readout on an app with no compensation produces data that isn't that great?

You are entitled to opinions, but not facts.

 

I have looked at my new NPB BATTERY with both Dr Prius and Techstream and both show the metrics of a brand new battery. Super strong.
Somethings not right in Denmark with yours.

loose bolts
Corroded disconnect harness
Corroded sensors
Corroded ecu harness I assume you took the cover off the ecu and removed the ecu Circuit board and looked for corrosion closely on the board.

it should come out for autopsy you may have a bad module but I doubt it.
Find out now.

to all prospective new Prius battery buyers check the voltage across all new battery’s before installing them they should be close. I did they all looked identical.

also after building it before you install it in the car install it’s safety switch and measure the total pack B+ Across the battery side relay. Mine was 220 volts.

then don’t forget to remove the safety switch before installing it.

And always After putting it in the car Even if your 100% positive the safety switch is out still measure it again at the relay before installing car side connections when installing it.

 

lol another cop out answer! i feel sorry for this guy, im going to leave it at that.

 

A couple of images that show some of what is possible, if visible on the outside you may want to look inside the HV battery ECU.

 

Everyone in that battery should check out the ecu. Here's some photos of mine when I installed my NPB months ago. I was shocked to see how clean the board & connectors were. Its a garaged car so I guess that helps somewhat.
But in addition to the outside connector sockets look closely around these pins these rot too.