Gen 1 2002 CEL OBDII Code P1636 HV ECU Malfunction

I think I do it a little differently than Bob recommends. I go to a safe place and slip the brake as I keep it floored allowing it to creep backwards. I can get up to 45A load, which drains the battery quick. The combined charge and discharge test takes me less than 10 minutes... another few minutes to do the final charge as Bob recommends.

Steve

 

The only difference is I prefer to minimize the current going in and out of the battery. Heat is the enemy but sometimes 'she who must be obeyed' gets a vote too. <GRINS>

Bob Wilson

 

I typically see 20-30A with very gentle driving and Techstream recording. I don't think 45A for a few minutes is an issue. If it is an issue to a particular battery, I'm of the mind there's a pending failure regardless of what is done.

Steve

Bob,

As I'm wrapping my conversion up, what needs to be modified? I'm not seeing anything that jumps out at me. I was going to replace the seal as someone prior tore off a couple chunks of it.

Thanks,

Steve

 

There may be an interference with the sides of the covers. I've not had to make the mod myself but when you go to assemble it, you'll find out.

So far, no one has posted what they did. However, the first ReInVolt pack had a bolt alignment problem that a little 'vice grip' persuasion cured. <grins>

It can't be that hard as so many have already been done.

Bob Wilson

 

Thank you Bob. There are definitely a couple areas of concern. I'll try to expand the community's knowledge base.

Draco,

I just load tested my Gen1 here:

Correct me if I&#039;m wrong... (new Gen1 owner) | Page 4 | PriusChat

 

The biggest risk are the sense wires. The leaked KOH can 'eat' the copper under the insulation. This leads to a broken sense wire and bad voltage reading in the future.

GOOD LUCK!
Bob Wilson

 

Bob has it. Pull ALL the bus bars before you attempt cleaning, or you'll complete some circuits you didn't want to. That looks about as bad as mine did. If you have any battery acid, soak the bus bars for a while. It won't touch the copper. Rinse and dry them. Scrape off the sealant and lastly hit with scotchbrite.

Make sure you clean the contact faces of the battery terminals too. Don't remove the sealant.

I wouldn't worry about the IR numbers. You're dealing with reduced capacity. Can you upload a CSV export of your load test? You'll have to rename it as a ZIP file.

Steve

 

The sealing job was to address the Gen1 propensity for terminal leaks. As nasty as it is, you should be glad it's there and leave it alone.

It was charging/discharging because of the circular pattern of clean copper you see on each bus bar. It was evident on both the front and the back side. As Bob mentioned, the issue is more with the sensing wires. They are so small and fragile, they can be adversely affected by corrosion.

You have already invested so much time and effort into this pack, I hate to see you stop at just replacing suspect modules. You'll likely be here again inside a year.

I would LOVE to see an exported CSV of your data on your load test.

 

I just realized you posted a load test chart up the page...

You need to address blocks 15, 16 and 17. You should probably address 10 and 18:



EDIT: corrected voltage for block 8.

 

I think Steve had a typo on block #8 . Under the 46.82 amp load the voltage was 13.74, not 13.47 volts. The discharge test is just half of what can be done. Do a charge test. The same modules that were low should then be high. Most likely just one of the modules in each block is bad.

Statements like this scare the bejesus out of me. The inference is that you think it is safe to remove the orange plug and then go poking around the bus bars with a DVM. Worse is that someone else could read it and think that pulling the plug makes the battery safe.

High voltage is present until all the bus bars are removed from one side of the battery.

While removing the bus bars you are working with live high voltage.

Most people selling modules on Ebay have no idea how to test them. Static voltage does not tell the whole story.

Brad

 

Brad,

Thanks for catching that. He's correct. Fat-fingered #8. #8 is fine. 16, 17, 15, 10, 18 in that order.

Brad also has it right that the flip-side can provide further confirmation or yield additional issues.

And if 2 times isn't enough, he's right again... safety plug only cuts the pack voltage down. It's still potentially lethal.

I'll chart your test shortly.

Steve

 

I took a look at the data. It's a bit messy. I'm not sure why, but your sampling rate is about 8 seconds... The discharge portion shows nothing new. I found 52 seconds of ~12A charging. Unfortunately, it peaks at about 55% SoC, so the block Voltage distribution won't change much. Your version of Techstream is spitting out CSV files in an almost undecipherable way at least in terms of delimiters.



Very busy chart. I didn't label them all.

12A isn't much to go on, so nothing can be gleaned from the above, but it's illustrative of what you can chart.

Steve

 

I am not sure what you posted here.

To do a forced charge test have the car running and Techstream hooked up. Get in the live data for the battery. Set the parking brake and put the transmission in drive. Step on the brake and gas pedal fully. Take a picture of the Techstream screen. Please post the results.

Brad

 

I'm OK with 15, 16, 17, and 18. I suspect 16 has been running hottest so it would have heated 15 and 17 for sure. But 8 has me scratching my head. Why 8?

FYI, weak is not a failed cell, yet. Loss of 1.2V in a module pair and one has died.

Bob Wilson

I am unable to unzip this file with either Linux or 7-Zip.

Linux reports:
unzip 98649_2002_Prius_1NZ-FXE_12-21-2015_90556_AM.zip
Archive: 98649_2002_Prius_1NZ-FXE_12-21-2015_90556_AM.zip
End-of-central-directory signature not found. Either this file is not
a zipfile, or it constitutes one disk of a multi-part archive. In the
latter case the central directory and zipfile comment will be found on
the last disk(s) of this archive.
unzip: cannot find zipfile directory in one of 98649_2002_Prius_1NZ-FXE_12-21-2015_90556_AM.zip or
98649_2002_Prius_1NZ-FXE_12-21-2015_90556_AM.zip.zip, and cannot find 98649_2002_Prius_1NZ-FXE_12-21-2015_90556_AM.zip.ZIP, period.

Bob Wilson