Current State of the Art in Battery Balancers?

Thanks.

 

It would be interesting to see your start to finish process written out, even if it was a condensed version

Finally got the battery reconditioned and into the Lexus. The Dr Prius full battery test was good. The life expectancy is good but it says 102% life which I'm guessing is inaccurate. It was tested right after install so expect the mAh to go down.

Do you match battery blocks by putting high / low modules in each block for overall balance? What measurement do you use to determine high / low modules?

How many cycles of discharge / charge do you usually do?

 

Do not attempt to charge loose unclamped Prius modules. They will swell up to where they look like a large Subway sandwich. The one exception to this rule is that if you limit charging current to <600mA and make sure the module isn’t getting more than 10 degrees above ambient.

Years ago I bought a pair of the white plastic end plates for the Prius HV pack on eBay. I usually stack 6 modules between the end plates. I clamp them with 4 long bolts and nuts. I never had any modules get bloated with this setup.

 

Lately, I've been starting with a discharge (to save time), then a charge, and so on for 3 cycles. 2 cycles is not enough, the voltage between the modules varies by 0.05 volts. One module is 8.00 volts, and the next one is 8.05 volts, and so on.
It looks like this
8.00
8.05
8.00
8.05

After three cycles, the voltage across modules usually looks like this
8.00
8.01
8.00
8.00
8.01
8.00

Battery packs that just need capacity restored I do 3 cycles and after working on bus bars, I install it back into the car.

Batteries that have trouble codes, I pinpoint bad modules in them, replace them, do bus bar work and then do 3 cycles, after that I put it into the car, discharge it to 40% and after 10 minutes I measure the voltage on the modules, looking so that there are no modules with a voltage lower than the rest by 0.1 volts or more.

If a battery pack has a single P0A80 code, such a battery usually does not have obviously bad modules. I do 3 cycles, then I dothe bus bar work, after that I put it into the car, discharge it to 40% and after 10 minutes I measure the voltage on the modules, looking so that there are no modules with a voltage lower than the others by 0.1 volts or more.

When a battery pack is old or with high mileage, I disassemble it and weigh each module by writing the weight on top of the module. I recently changed a battery pack in a 2012 Lexus ct200h with 195k miles. The battery pack with a single code P0A80. I weighed the modules and their weight was 1031-1034 grams, mostly 1033-1034 grams. Such a battery may still last for a couple of years, but you shouldn't rely on it much anymore.

102% means that the recovery process has worked. This percentage will decrease and on a healthy battery it should stop at 70+% and it will stay that way for several years. The similar thing happens to module voltage. On a healthy battery sitting on a shelf, the voltage does not drop below 7.7 volts, even after a year.