Current State of the Art in Battery Balancers?

Hayslayer · Jul 29, 2025 at 12:27 AM

Just in case anyone is looking, the G9510-47063 hybrid battery (2010-2011 probably others gen3 prius) is now available for $1535 new. The 28 modules inside are 100% interchangeable with the Gen 2. You can essentially have a brand new Gen 2 battery, built with the latest Gen modules if you're able to DIY the module swap. You'd probably want to buy a new sensor harness also for about $60.

PriusTech · Jul 29, 2025 at 3:53 AM

Carall said: ↑

You need to find the reason why it didn't work, rather than panic. You already have the Prolong charger. That's all you need to restore the battery capacity along with replacing bad modules. The discharger that discharges only up to 84 volts... to me it's useless, but even after discharging to 84 volts, the result will not be bad. The battery with 125k miles shouldn't be that dead. I tried to restore a battery from a 2013 prius with 186k miles. The owner was told first of all that the battery needed to be replaced, as the battery filter was clogged badly and the Dr. prius test showed 13% of life. After three cycles the dr. prius test showed over 60% of life, with still 5 weak modules in the pack that needed to be replaced.
Have you cleared the P0A80 code from the hybrid computer? Gen 3 does not erase the P0A80 code until it is erased with a scanner. If the code was erased and reappeared, what was the percentage of delta soc?
What voltage was the battery charged to at each cycle?
Has the battery cooling been used? If you do not use cooling, the battery will heat up and the charge will go into heat, and the voltage will not even reach 235 volts. On a low miles battery, the voltage reaches 237-239 volts. On a worn battery, it can reach 243 volts.
You don't need to cycle it 5 times. 3 times is enough while 1 cycle is not enough.
If this is an original battery with all original modules, then the difference between the modules should be not higher than 0.03 volts after cycling it 3 times. Discharge the entire battery to 40%, wait 10 minutes until the voltage settles and measure the voltage on each module. The lowest voltage on a bad module will be visible.
Click to expand...

I'm still learning how to identify bad modules.

I cleared the P0A80 with a generic code reader and by disconnecting the 12V small battery, it keeps coming back

The Delta SOC was 40

All three cycles the battery was charged to 237V - 238V

I had the metal cover off and a box house fan on top running on medium for the entire process

The before charge-discharge-balance volt test showed a .05V difference between high and low modules. (Picture on my post #36 above)

The after charge volt test also shows a .05V diff between high and low modules. (pic attached)

Haven't done a volt test after discharge, will do so. So any module that is lower than .03V from the highest module is suspect bad?

Current State of the Art in Battery Balancers?

Hayslayer Member

PriusTech Member

Attached Files:

LEXUS-BATT-TEST.jpg

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Current State of the Art in Battery Balancers?

Hayslayer Member

PriusTech Member

Attached Files:

LEXUS-BATT-TEST.jpg