Error P0A80, P3019, Exploding Battery, Hybrid Automotive

Hi All:
I've been through a whirlwind of stuff with my hybrid battery. I started getting the P0A80 code and deduced a module failure. Rather than simply replace the module, I decided to try the Hybrid Automotive Prolong Deluxe Reconditioning Discharge and Charge system package. I ran this a couple of times on the hybrid battery. I had difficulties with the system because the voltages would not discharge to the selections on the discharger. Also, although the charger is supposed to charge and balance all 28 modules in the hybrid battery, the system never does indicate "when" this actually finishes and Hybrid Automotive doesn't exactly know either. I ran the entire protocol twice but concluded with the P3019 error code coming up. So, I tore the battery apart and replaced the bad module. I did not do it's pair as it's charge appeared to be on par with the rest of the modules. I cleared the errors codes and got the system to not report any disfunction so I took it for a drive. I got the mph up to 40 and heard a really loud pop, followed by a second pop 5 seconds later. I turned and looked and saw smoke coming from the battery. Lucky I was right near my house and pulled back in the driveway. I tore the battery apart again and discovered that two completely different modules had exploded. Does anyone have an idea about what may have caused this to happen? I checked my work. Everything was put back together correctly. There were no shorts or loose contacts. I did not clean the bars or screws but I will do that now if I decide to just try to replace those two modules, but that would only affect resistance. When I checked the voltages of the modules after the explosion, one of the modules that exploded was down to like 6.4 I think, but the other was still at 7.5. ???

TIA

 

Thanks for the response guys.

146k. I unhooked the charger about 20 before running and test driving the car. The last discharge voltage was 189v. Final charge voltage was 234v.
It's one of the issues I have with Prolong discharge. The first discharge selection is supposed to be 134v but it never goes that low. I didn't do a complete 3 cycles of the discharge/charge because I'd already done that twice. I was only concerned with brining the new battery into balance with the others.

I did not use a specific torque on the bus bars. I did them by hand. I did consider this to be an overheating problem because it happened when I was going 40mph. There was no problem before that. I was noticing that the car wasn't accelerating properly which is why I opened it up a little because I was trying to determine what the symptoms actually were. I was also waiting to see if the dash lights were going to indicate the throwing of an error code to help diagnose.

 

The first time I ran the entire discharge/charge protocol to see if it would restore the bad module, I never saw that charge get higher than 236v and I was checking. I ran it for 26 hours, checking over and over to see what it was doing. I exchanged a number of emails with the Hybrid Automotive team about it and they gave me a number of reasons for this, none of which were satisfactory. So, I tried doing the entire protocol over again to see if something would change. It didn't. I was watching the discharge values and never saw a "bounce" like you describe. At least the system beeps when it's complete with the discharge. The charge... I would just let run for at least 24 hours because there's no way to determine if it's done. One thing I did continually notice is that when you let the charger run for 24 hours or more, it does peak out at a value and then that value starts to degrade. They say that 24 hours should be the maximum amount of time that you have to run the system. Once my charges decreased to the low 230's I would just stop it. I never saw it reach 240v. My most recent charge ran for 24 hours.

 

I can properly clean the bars and nuts and reassemble with new modules and proper torque if you think it's worth a try. I really don't have the money for a new hybrid battery unless I tried to pick one out of a yard somewhere close by. The last charge cycle peaked out at 234v but the car didn't seem to find that a problem. I would assume that the car would take care of charging the system to its fullest once I'm driving it again.

 

I can let it sit for a week. It's already out of the car and on the table right now. The car's already been out of commission for 3 weeks. 1 more won't kill me. So, I'll need to replace 6 modules then is what you're thinking? I could rig up a load tester. I just ruined a voltmeter cord accidentally today so I could create an inline light tester with some alligator clips and the meter.

 

That's a great idea. $15. Done.

 

I actually waited until the next day to drive it so it sat for at least 9-10 hours. I'll try the AC next time. I probably idled it for 5 minus. I'll extend that too.

 

I never pulled the entire buss assembly apart. I only released the nuts and buss bars on modules 10-13 to release #11. It was 21 and 24 that exploded, so torque wasn't a factor. I'm truly mystified about why those modules blew and that no error codes were thrown. It's as if some regulator malfunctioned. Maybe implementing ericbecky's suggestion with give me more data next time.