P0A80 with good block voltages?

The best way to understand what ou are dealing with is to get a Prius aware scanner (Techstream for example) and get the codes read .

Until you get all the codes, you won’t know what you are working with and then you’ll be fishing at solutions. There are many reasons for the triangle to pop up and to get the P0A80 code.

Since you’ve been in the battery before:

• What torque did you use to put the bus bars back together?
• Any leakage of modules?
• The hv fan was cleaned?

Best to get the codes read and let us know what they are for the next steps.

 

The screenshot you attached show battery blocks under an aggressive charge, put the car in neutral and turn on the A/C to put a drain on the battery and then look at block voltages. Might want to add a gauge for current draw from the battery instead of that HV charge gauge.

You can also look at the freeze frame data, it will show you which block triggered the code, my guess #8.

 

you don't have to open the pack to clean the fan, and check the intake grille as well.

 

The torque spec is 48 Inch pounds .

So you’ve gotten them 2x tightened .

Have you been able to get any data when the code sets as it could be intermittent?

Keep us posted .

 

On your run ac in neutral test I see the battery is getting hot and the hv fan is not even running.
There’s Something whacky going on your not seeing with torque. No delta on old battery with load.

Quickest techstream device you can get is called VXDIAG sold on amazon. $99.. It’s called VXDIAG WITH TECHSTREAM. It works good it is the obd dongle that plugs into the obd port. Then you plug that obd Device into a laptop via usb and you have full techstream.

How corroded was the battery interconnect? If it was really bad it may have rotted out the battery temp sensors under the modules or corroded the big battery ecu plug.

Take lots of pictures next time you go into that battery.

 

Looks like your problem is with block 1, lowest value recorded is 11.9, thats 5.95v per module. You have a few other weak ones in there as well, anything below 13v seems suspect. I don't think you have enough data though, you need to obtain a larger sample size and logging data instead of seeing current/lowest/highest. Download Hybrid Assistant/Reporter and generate a report of you driving for 10 minutes (after clearing the P0a80 code), should show you exactly which block is suspect and also show you any weak blocks.

 

This may be one of the luckiest HV batteries. It's not often a Block 1 module is first to fail. Easiest to get to of them all. If you assume (yikes) that the other module of the pair is equivalent to the average of the other ones that appear good then it should have been around 6.75v at the max load/min voltage point. That leaves the trouble module around 5.2v give or take. Plenty enough to trigger the triangle. HBE is right, as block 2, 4, 7 look like they each probably have a weak module or two. They'll probably be next in line for the whack...