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P3000-123 and P0A80 after hybrid battery reconditioning and rebalancing

Discussion in 'Gen 2 Prius Technical Discussion' started by bbellgrl, Sep 3, 2024 at 9:53 PM.

  1. bbellgrl

    bbellgrl New Member

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    After a lengthy hybrid pack rebalancing with an EV-Peak BGUAD CQ3 Multi Charger, every module had over 7500 mAh capacity on charge, and 5000 mAh on discharge. I found just one module that had under 5,000 mAh capacity on discharge and bought a replacement on eBay that tested perfectly when I received it. I replaced the lower capacity cell, then rebalanced, then found another error that led me to a single module that was leaking through its anchor/screw receptacle on its underside. Just to see what would happen, i replaced the leaky module with my lower-capacity module that I had previously replaced.

    After remounting the pack, everything seemed fine until after a 20-minute drive, the red triangle popped up again and gave me a P3000 and a P0A80. I checked all the plugs for corrosion and didn't find much other than a tiny bit of green on one of them (see attached photo). I disconnected the 12V for a while which cleared the codes, but they came right back. I just drove the car again and it drives just fine, but I had the Dr. Prius app live monitoring my drive and saw the "Pack Voltage" block turn red as the voltage exceeded 250 (it was at 252.4).

    Voltage difference on my modules is .13 as reported by the Dr. Prius app.
    Techstream shows module resistance as 19 ohms across all 28 modules. I've attached some screenshots.

    I'm at a loss as to what to do next. I'm wondering if the problem is related to the slightly lower capacity module I put back into the pack. I'm so close to pulling the trigger on a refurb pack from a good vendor, but with all of my modules having tested so strongly after multiple reconditioning rounds, I feel like my pack still has some life left in it (my car has only 148k miles), and I don't know if the refurb pack will resolve these error codes anyway.
     

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    #1 bbellgrl, Sep 3, 2024 at 9:53 PM
  2. Tombukt2

    Tombukt2 Senior Member

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    Try another battery computer
     
    #2 Tombukt2, Sep 3, 2024 at 10:23 PM
  3. bbellgrl

    bbellgrl New Member

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    What do you mean by battery computer ?
     
    #3 bbellgrl, Sep 3, 2024 at 10:25 PM
  4. mr_guy_mann

    mr_guy_mann Senior Member

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    You'll want to clean that corrosion and treat the connection with good dielectric grease. Then reseal the cracked body seam filler around the tailgate hatch.

    However, that has nothing to do with your present codes. I would click on the snowflake symbol next to the code in Techstream- that's freezeframe data. It should shed some light on what the ecu saw when it set the code.

    P0A80 almost always sets when the battery ecu sees the difference in block voltages of greater than 0.3V for "too long" (whatever Toyota says that is).

    Dr Prius is useful for quick visual monitoring of battery operation. Most faults show up during heavy accel (discharge) - particularly when State Of Charge is lower.

    It might be just the paid version of the app, but Dr Prius can datalog while you drive. Then you can review the data to see what's going on with voltages.

    Also, it's normal for pack voltage to go "very" high (250-270V) during heavy decel - charging. If the voltage was 250+V with zero amps, then it certainly would "be in the red" (and maybe set codes).

    The high voltage battery ecu is the silver aluminum box next to the contactor relays in the pack housing. It monitors battery pack conditions and sends the data to the hybrid control ecu (also controls the battery fan).

    A not uncommon fault is that the orange connector (for the block voltage sense harness) gets corroded and skews the readings. Sometimes minor corrosion can be "cleaned". Other times the harness and ecu must be replaced.

    Posted via the PriusChat mobile app.
     
    #4 mr_guy_mann, Sep 3, 2024 at 10:32 PM
    Last edited: Sep 3, 2024 at 10:45 PM
  5. MAX2

    MAX2 Member

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    According to the photo, Dr. Prius battery is unbalanced.
    Try the Hybrid Assistant app for Android.
    It is free and allows you to read data from different systems, generate reports. Including the high-voltage battery in dynamics. This will be informative.

    Techstream always shows 19 milliOhm internal resistance after disconnecting 12V.
    It is recalculated based on the results of the trips.
     
    #5 MAX2, Sep 3, 2024 at 11:01 PM
  6. dolj

    dolj Senior Member

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    Disagree. The difference in voltage between the highest and lowest block is only 0.13 V.

    The way the Dr. Prius app graphs block voltages visually exaggerates the differences, more so when the differences are small, something I personally do not like.
     
    #6 dolj, Sep 4, 2024 at 3:25 AM
  7. MAX2

    MAX2 Member

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    The error is determined by the difference of 0.3V between adjacent blocks. Dr. Prius does not show the frozen state that occurred during the error.
    In the photo, the difference between the smallest 1 (17.88) and 10 (18.16).
    I also use Hybrid Assistant to check the battery for suitability.
    This is more visual.
    Help me understand my Hybrid Assistant battery health report | PriusChat
     
    #7 MAX2, Sep 4, 2024 at 3:48 AM
  8. dolj

    dolj Senior Member

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    Dr. Prius is not that good at math then.
     
    #8 dolj, Sep 4, 2024 at 4:20 AM
  9. MAX2

    MAX2 Member

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    Dr. Prius use some of their own complex approximations and formulas.
    Hybrid Assistant simply records the data stream and outputs it to the Reporter in the form of a graph and table
     
    #9 MAX2, Sep 4, 2024 at 4:32 AM
  10. bbellgrl

    bbellgrl New Member

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    Thanks to everyone for the replies. I'll get in there tonight or tomorrow with Hybrid Assistant, and I also intend to remove the high voltage battery ECU to check for harness issues. Will follow up with updates.
     
    #10 bbellgrl, Sep 4, 2024 at 5:49 PM
    bisco likes this.
  11. bbellgrl

    bbellgrl New Member

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    I'm not finding an app called "Hybrid Assistant" on the Android app store. Could it be called "Doctor Hybrid"?
     
    #11 bbellgrl, Sep 5, 2024 at 4:52 PM
  12. Brian1954

    Brian1954 Active Member

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    No, it is called Hybrid Assistant. Here is the link to their website: Hybrid Assistant: App

    You can read about the app, then you can go to the tab "Download"
     
    #12 Brian1954, Sep 5, 2024 at 5:36 PM
  13. mr_guy_mann

    mr_guy_mann Senior Member

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    #13 mr_guy_mann, Sep 5, 2024 at 5:39 PM
  14. bbellgrl

    bbellgrl New Member

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    Perfect thank you. I have installed the app and I went on a short drive. When I started, the P3000 code was still in the system so I cleared it with the Dr. Prius app. Throughout the drive, no further errors occurred, and no red triangle or errors appeared on the display or dashboard. However, a few weeks ago, I cleared the P3000 and it came back after I reassembled the car, so I have no reason to think that won't happen again this time. Don't want to make the same mistake twice.

    I did check the orange harness that plugs into the battery ECU. No corrosion or issues on either side of the plug or receptacle. All looked great.

    I attached a screenshot of the battery data from the Hybrid Assistant app. Note that the voltage difference is quite small now. Throughout the drive, the highest SOC I saw was 48% or maybe 49%. It never hit 50%. Is that normal?

    Now that I have a Hybrid Assistant report, what exactly should I look for?
     

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    #14 bbellgrl, Sep 5, 2024 at 6:38 PM
    Last edited: Sep 5, 2024 at 6:51 PM
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