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06 HV Battery Module Replacement

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by dr3wst3r, Jun 17, 2017.

  1. dr3wst3r

    dr3wst3r Junior Member

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    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.

    Posted via the PriusChat mobile app.
     
  2. dolj

    dolj Senior Member

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    Do you have the safety interlock installed (and lock down) correctly?
     
  3. dr3wst3r

    dr3wst3r Junior Member

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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?
     
  4. JC91006

    JC91006 Senior Member

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    Did you replace any modules? You should read the codes, forget the grid charger for now
     
  5. dr3wst3r

    dr3wst3r Junior Member

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    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.
     
  6. JC91006

    JC91006 Senior Member

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    Read the codes and see what the error is now.

    EBay....That might be a problem

    Did you charge before discharging?

    You did all this in the last 6 days? Replace module, charge 3 cycles?
     
  7. dr3wst3r

    dr3wst3r Junior Member

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    Yes I did a charge and balance before doing the discharging. I hope that is not the case.
     
  8. JC91006

    JC91006 Senior Member

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    If you read the codes, it'll tell you your problem. If it's block 8 again, then you should load test that block.
     
  9. JC91006

    JC91006 Senior Member

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    What is the total time you spent charging your battery from 40v to 235v? If you did 12 hours and then discharge again, then that might be your problem too. What current did you use going down to 40v?

    Whenever you are dealing with an entire pack of modules, every cell has to be balanced and equal before you discharge. If any 1 cell out of the 168 cells get damaged because of reverse charging, then your entire battery pack will fail because of that 1 cell.
     
    jerrymildred likes this.
  10. dr3wst3r

    dr3wst3r Junior Member

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    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?
     
  11. JC91006

    JC91006 Senior Member

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    Where did you get the grid charger setup? The x2 75w bulbs are way too high of current going down to 40v. You should be using 25w. Your cutoff voltage points were a bit off, not sure if that'll affect much.

    From 40v to 235v, should've taken about 18 hours. So you were not at 235v when you discharged again to 20v. What you saw on the screen is not really accurate when it comes to Nimh batteries

    Anyways, what's done is done. Read your codes and see which ones are weak (under load). Then change it out.
     
    #31 JC91006, Jun 25, 2017
    Last edited: Jun 25, 2017
  12. ericbecky

    ericbecky Hybrid Battery Hero

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    Do you have the ability to see the data live?
     
  13. dr3wst3r

    dr3wst3r Junior Member

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    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?
     
  14. ericbecky

    ericbecky Hybrid Battery Hero

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    As others said, read the codes.
    Then, depending what you find, you can look at the hybrid battery data live while fully charging the battery by "power braking" while in "D". Also can watch while discharging the pack in "R"
     
  15. dr3wst3r

    dr3wst3r Junior Member

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    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- full pedal discharge.PNG

    "Power Break" Charge-
    Power break full.PNG
     
  16. JC91006

    JC91006 Senior Member

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    Looking at your data from post #1, I can't see how block 14 is bad. But your new data after your reconditioning, 14 is definitely an issue.

    Your pack is still quite unbalanced. You have to charge it for a longer period of time to give the weaker cells a chance to fully charge
     
  17. dr3wst3r

    dr3wst3r Junior Member

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    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?
     
  18. JC91006

    JC91006 Senior Member

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    I believe at least 1 of the modules in 14 is bad. I personally would replace both of the modules in 14 with a matching pair. Keep the good one from block 14 as a spare.

    The way you charged and balance your pack could have affected it. Remember the pack has 168 cells in 28 modules. If any one of those cells go bad, your entire pack is useless. You have to charge and balance every one of those 168 cells and get them to 100% charged before you begin a discharge. Discharging a weak cell can reverse charge it and damage would occur.

    Hybrid automotive website has good instructions and guidelines to follow. If you want to review all the steps and cut off points on discharges, that should help you.

    Connectivity can be an issue if you didn't tighten nuts to 48in pounds
     
  19. dr3wst3r

    dr3wst3r Junior Member

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    Thank you much for all of your help. Do you have a preferred vender for modules?
     
  20. JC91006

    JC91006 Senior Member

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    yes. me