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New hybrid battery

Discussion in 'Gen 2 Prius Technical Discussion' started by ruidboi, Sep 1, 2014.

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  1. MTL_hihy

    MTL_hihy Active Member

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    You don't need any specialized (rubberized) tools for this work because when done on the bench there's plenty of room to use extensions which keep everything clear of contacting anything. I suspect in this case that the OP didn't take the time to remove the battery to the bench and working on it while still in the car is what caused this accident. Had it been on the bench I doubt this would have happened but often taking short cuts you live and learn.

    Once you pull the safety plug you can disconnect all the ECU, relays, etc safely. Then the battery should be removed as a whole from the vehicle and then remove the bus bars on the bench to make the modules safe for handling.
     
    #61 MTL_hihy, Oct 16, 2014
    Last edited: Oct 16, 2014
  2. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    You can never completely isolate yourself from exposure to electricity when working on an hv battery. In order for it to be isolated, it has to be disconnected. Even one module has 7.2+V and is capable of high amp (for a short time). You just have to respect it and take precautions. Its pretty clear that the wrench shorted out on something while being connected to one of the positive connections. This is not particularly dangerous to the individual because electricity will take the path of least resistance. It will however scare the hell out of you. It will also cause surfaces to heat up quickly and may burn you but, electrically, not particularly dangerous.

    I will say that you must take all precautions to avoid this at all costs. It could harm the battery, wiring, electronics etc. Be careful.
     
    #62 usnavystgc, Oct 16, 2014
  3. SageBrush

    SageBrush Senior Member

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    How about the instance where the person is not handling modules, just switching the harness/ECU/relays from one pack to another ?
    I'm trying to imagine this since I do not have a picture or the pack to look at. Why do you say to disconnect the ECU/relays before removing the whole from the vehicle ?
     
    #63 SageBrush, Oct 16, 2014
  4. MTL_hihy

    MTL_hihy Active Member

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    Suggested Steps:
    1) Remove safety plug
    2) Open battery case
    3) Disconnect everything from junction block
    4) Remove battery from vehicle
    5) Remove bus bars
    6) Modules are ready for testing or you can swap items to new battery
     
    #64 MTL_hihy, Oct 16, 2014
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  5. SageBrush

    SageBrush Senior Member

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    Question from a dummie: why do you open the case and disconnect the cables from the junction block in the car, rather than on the bench ?
     
    #65 SageBrush, Oct 16, 2014
  6. JC91006

    JC91006 Senior Member

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    The ECU and relays are separated from the modules, in a separate compartment. You won't have to touch the modules at all if you are only switching ECU and relays over.
     
    #66 JC91006, Oct 16, 2014
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  7. SageBrush

    SageBrush Senior Member

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    So what was ruidboi doing ?

    I wonder if he had to also move over those pretty bright orange cables
     
    #67 SageBrush, Oct 16, 2014
  8. JC91006

    JC91006 Senior Member

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    read from post #33 onward. He had issues with his battery after installation.
     
    #68 JC91006, Oct 16, 2014
  9. JC91006

    JC91006 Senior Member

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    #69 JC91006, Oct 16, 2014
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  10. SageBrush

    SageBrush Senior Member

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    I read, but he was not sure what the source of the error was. It sounded like he had fiddled with the busbars/voltage sensors and went back to check their torques when the spark occurred. This is part I'm trying to understand because his original job was to simply put the old ECU/harness/electronics into the new pack.
     
    #70 SageBrush, Oct 16, 2014
  11. JC91006

    JC91006 Senior Member

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    I was quite confused too. Why would anything need to be tightened or torqued if it was a new battery. The module's should have been all factory installed, nothing to touch.
     
    #71 JC91006, Oct 16, 2014
  12. SageBrush

    SageBrush Senior Member

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    #72 SageBrush, Oct 16, 2014
  13. SageBrush

    SageBrush Senior Member

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    #73 SageBrush, Oct 16, 2014
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  14. ruidboi

    ruidboi Junior Member

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    The new battery did not come with the 2 Main battery cables or the service plug wire. That is what I installed in the new battery. Everything else was factory torqued. The car worked great for two weeks and then error lights with the p3030 code. So I researched the problem and people said it could either be bolts connecting the sense wires were not tight enough or cracks in one of the sense wire. All of the busbars and sense wires were new and factory torqued but I got the p3030 error after two weeks. So that is why I started unscrewing the factory torqued bolts and retightened with the torque wrench. I even tested two sense wires for continuity and resistance what I thought may have been the problem with my multimeter and they were fine. What do you think can cause P3030 error in a new battery? Is it possible to buy a Brand new main battery cable? If so where can get it? Also I'm not going near that battery unless I get High Voltage gloves. I hope I can find them on amazon.com.
     
    #74 ruidboi, Oct 16, 2014
  15. JC91006

    JC91006 Senior Member

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    When you're in a pinch and need something right away, you can get pretty good protection just doubling up on rubber dishwashing gloves.
     
    #75 JC91006, Oct 16, 2014
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  16. ruidboi

    ruidboi Junior Member

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    Your are absolutely correct. There is only one Toyota Dealer in my country and they don't know much about hybrids. When I originally had the problem the lights were on the dash and carried into them. They had my car for 1 week trying to figure out the problem. They eventually said it was the Hybrid battery ECU that needed to be changed and they gave me a quote for $2100. I then picked up my car and bought a scangauge 2. I pulled 2 different codes out with the scan gauge 2 P0A80 and P3021. Which means the hybrid battery needs to change not the ECU. So I will get a new battery cable, but What should I do about the p3030 code?
     
    #76 ruidboi, Oct 16, 2014
  17. SageBrush

    SageBrush Senior Member

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    ^^You have to now go over the battery and look for any cables damaged by the short circuit. Someone more expert than me can advise you regarding the modules.

    As for the p3030 code, well that is still a mystery. Are you using a new battery ECU or the one from your old pack ? Can you say whether the module's serial numbers are sequential ? You might have to inspect the sense wires while flexing and inspect the harness to uncover a discontinuity or other defect. Unfortunately that means disassembly of the module inter-connections.
     
    #77 SageBrush, Oct 16, 2014
    Last edited: Oct 16, 2014
  18. CARspec

    CARspec Junior Member

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    No. This is not a suitable alternative. Please don't do this. Wait and do it with the right gloves.
     
    #78 CARspec, Oct 16, 2014
  19. JC91006

    JC91006 Senior Member

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    Why is this not a suitable alternative?
     
    #79 JC91006, Oct 16, 2014
  20. ruidboi

    ruidboi Junior Member

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    Is there any place I can purchase a Brand new main battery cable?
     
    #80 ruidboi, Oct 16, 2014
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