The split of the service plug would make sense if they re-used the battery controller (BMS). Here's an image from the G2 unit I reverse-engineered: https://ingineerix.com/pic/?priusg2batecu
If you look lower left, you can see de-populated parts which comprise 6 additional voltage taps. For 10 modules, that would be 5 taps, so makes sense. The"break" for the service plug has to have a corresponding break in the voltage sense circuit, so this probably explains the location of the service plug on G2. On Tue, Jun 18, 2024 at 5:39 PM Cor van de Water <cor.vandewa...@gmail.com> wrote: > When you look at the gen2 hybrid pack, you see that it has the service > disconnect with 9 modules on one side and 19 on the other side. > Reason is that they simply chopped 10 modules out of one side of the > original 38 module pack of the gen1 to create the 28 module gen2. > Apparently that was less work than making 2 changes, one on each side > of the disconnect. > The resulting 270V pack gave the gen1 about 15kW of electrical power, > if I am not mistaken it reaches the redline of the MG1 at 42MPH and it > needs to turn the engine in order to downrev the motor. > Reason for the breakdowns in the armature of the MG2 predominantly is > the insulation which is not designed for the high frequent switching > of the inverter and (I heard) contamination of the splash-cooling oil > of the MGs which causes small magnetized metal parts to settle on > windings, making the fields concentrate on spots and/or the fast > mechanical movement of the wires due to the forces in the magnetic > fields that rub wires together until the insulation is worn through > and short circuits between windings occur. > I have replaced a handful of the MG2 which is a rather challenging > task with the vehicle on the ground and the weight of the motor. > I am in a similar situation as Lee, although I no longer have a gen1 > because all 3 that I had, were robbed of their catalytic converters > when those became unobtanium, so I sold all cheap for parts. but I do > have a pristine 2006 gen2 with 200,000 miles so the hybrid battery was > no longer repairable. I replaced it with a set of used modules and it > works again, but still has a weak hybrid pack. Hence my interest in > newpriusbatteries.com > > -------------- next part -------------- An HTML attachment was scrubbed... URL: <http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20240618/31c7d8dc/attachment.htm> _______________________________________________ Address messages to ev@lists.evdl.org No other addresses in TO and CC fields HELP: http://www.evdl.org/help/
