Current State of the Art in Battery Balancers?

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.

 

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?

 

How many hours did you charge the hybrid battery to achieve the 238v?

I do not think you charged the battery long enough to top balance the complete battery pack. Try charging the battery for 24 hours. The battery voltage should go to 243v to 245v and then it will decrease a few volts. Then, you know you have achieved balancing of all the cells in the battery pack. If you do a top balance of the battery correctly, the DELTA SOC should come down.

Read the online Prolong reconditioning instruction about top balancing the battery pack.

 

I think you may be right, Prolong says for the last topping and balancing it's around 24 hrs and up to 48 hrs. So on the last cycle it was 24 hrs, and it went from 125V to 238V, but never got higher. Between that and not finding the bad cells to replace is probably the issue