These two screen shots were taken within seconds of each other. Mostly I want to confirm that modules 2&3 are towards the passenger side of the car. (This is in a 2nd gen 2007 Prius)
Yes, #1 is furthest away for the ECU. From the images posted above, it looks like you're having issues with the #2 harness (corrosion or breakage), or something similar inside the HV ECU female connector socket/pcb. Trying replacing the harness, and clean the ECU.
There's two modules in each block, so you're looking at issues with block 2 & 3, which mean modules 3,4,5,6 but at least two of these modules are likely healthy and replacing all four of them at once will make it way harder to build a balanced pack. As a general rule replacing only one module per block is way less hassle. Of course the first step is cleaning out the corrosion inside your battery ECU and replacing your "wire, frame, No-2" so you're no longer getting false voltage readings.
Thanks for the info - I think you both are probably correct as this is a battery pack that I bought to work with for a spare. I had 40 modules to work with and cycled all 40 modules 5 times each then took the best to make up the 28 module pack. Then balanced the pack for 3 weeks so was a little surprised at the the results that were not so good. I've since pulled these modules out and re-tested and cycled them and there does not seem to be an issue with and of the modules. I'll look at cleaning the connections with some deoxit D5 and replacing the #2 harness as suggested. Is there an aftermarket harness kit that has known good results or is Toyota OEM the way to go? Thanks for your input.
No aftermarket harness, but OEM one is less than $100... Make sure to clean inside battery ECU, that's usually where the corrosion turns into a short-circuit that fries the ECU.
The battery pack is made up of 28 modules and each module contains 6 cells. That means the battery is made of 168 cells. Just so we're all on the same page.
