06 HV Battery Module Replacement

Ok well I put some dielectric grease on them so hopefully that will so slow down the corrosion. Does anyone know if there is a failsafe where the HV battery will not give power unless the cover is on. Looking at the main terminals I am thinking it has something to do with that small thin metal cover. I tried to check my handiwork but could not get power out to the car. Inner terminals(closest to the battery) had 217v but the outer had nothing.

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Ok well I completed the full recondition with discharges going down to 90V, 40V, and 20v respectively. Each time I would bring it back to about 235v or higher. MY final charge and balance was 24 hours.

Today, I took it out for a short drive to breakfast about 10mins, it was fine no lights or warnings. Battery even got up to green with the downhill. Then, on the way home, we cranked the AC and after about 5mins the Christmas light popped on and the battery began to drain quickly. The final bit to the house the car was struggling and battery was almost empty even with the AC off by then. When i got back home i threw it back on the Grid charger.

I have not had a chance to plug it into a VCI reader yet to check the codes. I am a bit frustrated after all the work. Any ideas?

 

Yes I replaced one before I did the full cycle. You can see the voltage test on page 1. I just replaced module number 8 with a module from ebay.

 

Yes I did a charge and balance before doing the discharging. I hope that is not the case.

 

When I charged it back up from 40V it was about 12 hours. I just waited for the pack to stabilize at 234 as I was under the impression that you did not need to balance during your cycles only at the final cycle. When I cycled the final time it was about 24hours and got to 238V.

For the discharge, I used 2x 72Watt bulbs and just changed the length of time for each discharge. There is a chance that I could have reversed charged the battery. When I had the bulbs on the final cycle it went very low like 10V as seen on the volt meter, but as soon as I plugged it into the grid charger the meter on their showed 25V. I know that since it was not under load it would spring back up.

If I were to have reverse charged the pack, what would be the best steps to bring it back or did I hose my self?

 

Yes, I have a Mini VCI, but of course my hubris was so that I let a friend borrow it. I am going to pick it up tomorrow. Any suggestions on what to look for?

 

Alright wizend Prius sages. Here are my error codes and a few snap shots of the Techstream. To get the car to error out again we drove around for about 10mins after doing some "Power Breaking" and Discharging as stated above in Eric's post. Based on my limited knowledge it looks like Block 14 is off and I am hoping that is what is leading to these other codes (Crosses Fingers).

Error Codes:
P3000- Battery Control System
P3024- Battery Block 14 becomes Weak
P0A80
C1310- HV System Malfunction
C1259- HV System Regenerative Malfunction
B1421- Solar Sensor Passengaer Side(AC)

All of these screen shots are prior to the Error code and tested before driving.

R Discharge-

"Power Break" Charge-

 

Is there any possibility that this could be a connectivity issue? Is the best best to go in and load test block 14 against a few others or do you think that this is something that could be balanced out?

 

Thank you much for all of your help. Do you have a preferred vender for modules?