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battery or ecu issue

Discussion in 'Gen 2 Prius Technical Discussion' started by dmprius, May 8, 2023.

  1. dmprius

    dmprius New Member

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    2007 Prius
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    Base
    I learned from this forum how to properly refurbish the original traction battery in my 07 and got a trouble free 3 more years out of it. Another module took a dump finally and I had already prepared as it showed symptoms by having a new nexcel lithium pack on the bench. Popped it in and, as advertised, went from 43 to 50 mpg. No issues on install or firing the car up and happily burned through a tank at around 50 mpg. Entire pack was well balanced in arrival and the vitals on dr prius looked great.
    I then packed the car for a trip west. A few hundred pounds of vacation gear and a relentless headwind and hills for 700 miles. Before the wind started mpg was identical, then dropped sharply with the wind and hills. Averaged 34-35 through a few tanks. As soon as the crap was unloaded and it was back to daily suburban driving in the flats with no wind I expected the mpg I was accustomed to but I’ve put two tanks through it and have yet to crack 40 mpg average once.
    The ice is insistent on charging the hv battery to the mid to high 60s % at all times, even under the load of a hill when it is needed most. More gas pedal will give me the amps if I get into it but as soon as I back off its back to throwing a few amps into the battery. Having watched the app for years on the old nimh pack and having watched it the first few hundred miles on this new pack with zero apparent difference, I can see something’s changed.
    So I’ve got a brand new pack, internal resistance, temp, available power is all spit on, but something happened during that drive or perhaps coincidentally at the same time and this new setup is now worse than my old clapped out desert nimh pack.
    I have disconnected the 12v pos/neg and all ecu connectors for half a day a couple times without change. I’ve forced the pack down to low 50 percent range to give some head room for ice warm up since it’s low ambient temps here compared to where I installed. It happily runs the ice to high 60s to 70% regardless and then occasionally keeps running to knock off some charge at a stop. Gets into the first green bar often. Has all the signs of an old pack but isn’t and has tons of power on demand.
    So is this ecu or is this in the boards in my new blades?
     
  2. TMR-JWAP

    TMR-JWAP Senior Member

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    @AzusaPrius is a resident expert on that battery pack. Since he's being tagged, hopefully he'll be along shortly to provide some technical help.
     
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  3. PriusCamper

    PriusCamper Senior Member

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    Welcome to the NexCell family... Your pack comes with a 2 year warranty, but so far the symptoms don't indicate there's a problem with the pack, but if you get an OBD2 reader and setup Dr. Prius App on your phone you could post some screenshots that will help us see the details of battery health.

    It's fairly normal on short trips around town in cooler than normal weather for Arizona to get low 40's MPG with both NiMH and Nexcell packs, but again, we can't say this is a problem with the pack until there's more information, as well as gas from a different gas station than the one you've been filling up at.

    Also has the engine had a tune up lately? How many miles on it?

    One method you could try while you get things setup for Dr. Prius app is resetting the MPG calculator once you're up to freeway speed and stay in the slow lane for 20 minutes or more, which will give you close to your best possible MPG.
     
  4. AzusaPrius

    AzusaPrius Senior Member

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    I wouldnt worry unless you have the check engine light showing codes for the battery.

    Also do you have version 1 or version 2 of the Nexcell battery?

    You may also want to check your brakes and fluid should be changed if it hasnt.

    This can point to the ICE coming on when it shouldnt and trying to charge/discharge the battery.

    Keep an eye on the Dr. Prius app and watch the cells for any red colors when braking.
     
  5. PriusCamper

    PriusCamper Senior Member

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    First batch of Version 2 upgrade kits and packs sold out in 28 minutes in April, so it's safe to assume that they have version 1 still... Next batch of upgrade kits (they improve MPG) arrive in a few weeks and there's some kind of significant discount for existing Nexcell owners.
     
  6. jzchen

    jzchen Newbie!

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    You’re driving around somewhere cold/colder than where you installed it. (What I interpreted from the post, if I’m not mistaken)?

    How much colder are we talking about? How cold are we talking about? (Might be helpful to know)…
     
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  7. AzusaPrius

    AzusaPrius Senior Member

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    @PriusCamper

    There was no mention of when he purchased the battery and this post is only hours old.

    I would not assume he has version 1 and I know how fast they sold out as I told everyone on release date to hurry and get one because it was a limited supply.
     
  8. dmprius

    dmprius New Member

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    It’s v2. Temps upper 50s to mid 60s. Been through many much colder winters which is when I had my highest mpg. Any temp effects were trivial relative to ac compressor effects in summer. The point is I’m confident if I pop the old pack in the trunk I’ll get 43-45 mpg driving it like a rental at a race track but some discreet event has occurred a few hundred miles after install that has the ecu intent on topping the voltage. Is there a memory capability in the module boards? Do the first hours or miles of use determine anything? Car is running absolutely top end everything 11/10. Getting 38.5 mpg no matter driving style now.