Normal corrosion on a 10-month old HV battery?

welcome!
i have no experience, but that doesn't look too bad. the thing is, there are rebuilt packs, and there are rebuilt packs. and even the best of them are iffy.

 

I'm going to assume that you didn't (or weren't permitted to) open the case before the most recent rebuilt pack was installed.

IMHO, the corrosion is several years old. It seems the rebuilder did little more than replace the bad modules and re-balanced them as assembled for this pack.

 

The rebuilder did exactly what u did to your previous battery, replaced s module never bothered cleaning it and shipped it. Whack a mole battery rebuilder. That corrosion is extensive and very old. That's original corrosion too not corrosion back on a previous cleaned battery. Hope you didn't spend a lot of money.

 

Those bus bars appear to have impressions from a nut with a ridged or serrated surface. I've never seen an OEM battery with that style fastener. At least they used new fasteners . I would not expect to see that level of corrosion buildup in 10 months, but I also don't have a lot of experience with the NJ climate's impact on bare copper bars either. But, I have a battery pack that I've had on equalizing for 6 months (experiment) and the beautiful shiny heavy gauge copper wire I installed is no longer shiny at all and has green buildup on it. Soooooo.........I'll withhold judgement as to whether they were cleaned or not.

 

Clearly that rebuilders chooses not to clean off the buss bars.
Whenever buying a "rebuilt" battery it is Buyer Beware if you are not getting it from a reputable company.

Can you please share the name of the place in NJ. Are they still in business? Inquiring minds want to know.

 

Before installing a replacement pack, all contacts should be cleaned including all male and female components. Generally every contact should be coated with a light coat of Vaseline. We have some great HV battery experts at PC, they can assist with all the aspects of troubleshooting and replacement and balancing. It's quite involved, requires special equipment and cannot be done overnight. Find a HV Bat restorer with at least a 1 yr warranty. Just replacing individual module(s) is not recommended.

 

Yea, that green mold seems almost alive, I believe it conducts also, in a short circuit way.

 

That is typical corrosion. And not that bad compared to many packs I've seen.

A large percentage of older cars are driving around with this much corrosion or more.

 

Next time apply some No-OX to all shiny parts and they will stay shiny.
Shiny is attacked very quickly.

 

Use No-OX instead of vasoline It is designed to protect metal from galvanic corrosion.

 

pristine.

 

Ty Ed like that No- Ox ...idation can be bought At ???

 

The condition of the outer casing is not critical. All elec. contacts must be dry and clean ..except for No-Ox.
Don't know, I assume that's totally conductive, I know Electra-Clean is.

 

Chris HV, interesting to see that some of the modules appears to be broken.
Looks like you got some real castoffs there.

Looks like the kind of bad modules that might get sent to recycling.

Too bad people can't know the quality of what they are buying. The, unfortunate, assumption is that all rebuilds are the same. This is a great example of how they are not.

I'd like to use at least one of your photos as education for others. Is that OK?

At least now you have an inkling what you are dealing with. Time to quantity how bad things are and decide how/if to save it.

Is this company still in business?
I hope not.

As always, feel free to call if you want to chat or bounce ideas about how to tackle the situation.

 

Falcon??????
Noooooooooooooooooooooooooooooooooooo!

Sorry to hear that.
Well, now it all makes sense why you are having to deal with all these issues.
Another example I'll have to add to my wall of shame.

That. said, I guess it did last as long as their stated warranty. So they upheld their end of the bargain.