Gen3 HV batteries for Gen2?

I'm sure somebody has rebuilt a second gen pack with third gen modules by now. I'd imagine it's like swapping second gen modules into a first gen pack. Might be a tighter squeeze but it will work. My plan is to locate a low mileage salvaged third gen pack when my HV battery fails and swap all of the modules out.

HTC Evo 3D

 

Considering the higher number of gen3 battery failures I'd question why you'd want to use them in a gen2.

 

Hi GrumppyCabbie,

I mostly hang out or peruse the Gen II section here. Haven't browsed over to the Gen III section much. Do we know if it's related to the design/manufacture of the modules themselves? My reasoning in Gen II vs. Gen III modules in a second gen pack would be that Gen III modules are obviously newer and there's more of a chance to find a low mileage pack from a wrecked vehicle.

In the meantime, my HV pack is still going strong and I don't have any reason to replace/repair it yet. If there is proof there is a problem with the actual Gen III modules themselves then I won't be taking that route when the time comes.

HTC Evo 3D

 

Outside my knowledge. Not sure if it's the modules themselves or that they are worked harder and get hotter causing premature failure.

 

I'm going to have to pay more attention to HV battery failures in the Gen IIIs. Thanks for the heads up!

HTC Evo 3D

 

The Gen3 modules have a lower series resistance and therefore are rated to handle 30% higher max current. The Gen3 ECU is programmed to push the HV battery harder which may contribute to the reported failures in heavy (taxi) applications. I tend to prefer Gen3 modules over Gen2 modules for a Gen2 HV battery rebuild, but then again, my rebuilt battery (a ReInVolt) with Gen2 modules is still working well after 60k miles and 2.5 years.

JeffD

 

Would you just happen to know if the cell module assemblies can be switched between Gen 2 and Gen 3 batteries?(I.e. Same shape, connections, etc.?)
Or if they differ in internal resistance would that be a very bad idea?

 

I would not mix Gen2 and Gen3 modules in a Gen2 battery, but the lower series resistance is a good thing - less heat generated. As far as I know, the Gen3 modules should mechanically fit in a Gen2 battery housing.

JeffD

 

The two batteries are built with different HW/SW interfaces to the rest of the Prius so I believe that this will not work.

You can do that and it should work as long as the salvaged Gen3 battery was in good shape. I would go through the balance/test procedure for my own Prius to insure a better chance of the repair lasting longer.

JeffD

 

I was told the same by Carolyn of Luscious Garage.

Lightly used Gen3 packs are so cheap right now I have thought more than fleetingly about swapping out the pack in my '04 Prius as a preventive maintenance, even though it runs just fine.

 

28 as well, the Prius "C" has fewer.

JeffD

 

Sounds like fun!

Maybe we East Coastians can do that also!

Any way to safely keep charge levels up if I purchase a pack now for use in a year or two? For lead acid I would use a trickle or float charger , but this is a different chemistry and way more volts.