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P0A80 on a rebuilt bttery back

Discussion in 'Gen 3 Prius Technical Discussion' started by Morpheous, Aug 6, 2022.

  1. Morpheous

    Morpheous Junior Member

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    Long story short, I actually own a Camry hybrid however 3rd Gen Prius is probably the closest fit in terms of cell age / vehicle technology.

    I have built a battery pack by combining 2 battery pack worth of cells from two Prius Cs. Donor car #1 - 115000kms with a full service history. Donor car #2 -98000kms with a full service history. I had every reason to believe the cell modules are in good nick as no odometer tampering has been performed. I took 20 cells from Donor car 1 and 14 cells from donor car 2, no cell mixing - just added one next to each other to form the 34 cell battery I needed.

    I used a Prolong charger/discharger to complete 3 charging cycles. Charge cycles generally ran for about 18 hours and discharge cycles until the discharger auto-beeped to end the discharging.

    I've fitted it into my car but after a while, it throws P0A80.

    - Yet to load test but resting voltage is very good with everything ranging in voltage from 7.85 - 7.90V.
    - Is there anything to infer based on pictures of the bus bars shown? In particular, note the blue deposit on the copper bus bar. Curious to know what this is?
    - Would buying a Skymax B6AC charger be the rest way to capacity test the modules?
    - Would the lightbulb test help at this point in time?

    Time is of no essence but I don't currently have a donor vehicle, so I am trying to work this out on a bench...

    Any tips or directions would be appreciated!
     

    Attached Files:

    #1 Morpheous, Aug 6, 2022
  2. Tombukt2

    Tombukt2 Senior Member

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    Yeah why is that there so this is a battery made out of two other batteries and I'm assuming you cleaned the bus bars and the terminals are the threaded studs of the batteries if not that's where we need to go back to that step The bus bars can be bought new in silver hard or metal or you can tumble the copper ones or whatever the original ones are and make them shiny again and new it's basically your choice I would use new nuts you could tumble them also but as cheap as they are I tend to push by set of nuts in the newer harder bus bars. Or are we saying this was all cleaned and this has happened on the bench? How are you getting a p 080 code? It had to be in the car at some point did the corrosion happen in the car so it was on when you took it back out of the car yeah that needs to be cleaned up that could be causing you problems for sure.
     
    #2 Tombukt2, Aug 6, 2022
  3. Morpheous

    Morpheous Junior Member

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    Sorry champ, I've tried to read your reply but it's difficult to understand what you mean.

    Corrosion happened whilst in the car, though seems accelerated for basically 4 weeks of use. Concerned a cell issue is causing this. E.g. overtightened nut, stripped thread etc.
     
    #3 Morpheous, Aug 7, 2022
  4. jerrymildred

    jerrymildred Senior Member

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    I'm not a pro at battery rebuilding, but the voltage looks fine to me according to your numbers. Internal resistance is another factor. Have you checked that?

    From the pictures, though, it looks like you need new bus bars and to clean those terminals. They are nasty. Cleaning the bus bars would help, but new ones would be a time saver and not very expensive.

    Also, there might be a problem in the sensor wires.
     
    #4 jerrymildred, Aug 7, 2022
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