UPDATED! Repaired Prius traction battery ; Warning lights

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by thomas4782, Aug 7, 2015.

  1. gdanner

    gdanner Member

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    Check for DTC code P3009.

    P3009 is the DTC code for a "ground fault" in the high-voltage circuit. The entire high-voltage section is completely isolated from ground. Any leakage current, even only a tiny bit, will cause the P3009 DTC code.

    One thing that might cause the P3009 code is a tiny bit of moisture (or vinegar solution) left behind from when you cleaned the busbars.
    Everything inside the HV battery case needs to be "surgically clean" and also totally 100% dry.

    The Priuschat post "rehydrating the cells" has more information about the P3009 code and also some tips for getting the HV battery pack clean enough and dry enough to prevent the P3009 error from occurring.

    -EB
     
  2. thomas4782

    thomas4782 Junior Member

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    Received my MiniVCI, set it up on the Prius.

    Since the 12V battery was unhooked, previous error codes were clear.

    Attempted to run the Active Test for the hybrid battery cooling fan - all my errors immediately pop!

    I am seeing an error P0A84 "Hybrid Batter Pack Cooling Fan 1 Control Circuit Low". Googling the issue seems like this one error will cause many others to show as well.

    Where to proceed from here?
     
  3. bisco

    bisco cookie crumbler

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    i think there is a troubleshooting tree at priustechnodata.com or something like that. you can rent for $15./day.
     
  4. thomas4782

    thomas4782 Junior Member

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    So I did a bit of looking around about the issue, came across this thread DASH Error Lights Exclamation w/Triangle, VSC, and small Exclamation - Car runs great? | Page 3 | PriusChat in which the thread starter was having similar error codes. The linked post is describing corrosion on the fan relay wire connector. I checked my car, and there is a decent amount of corrosion on all wires here.

    My thoughts are to remove or replace the corroded wiring, perhaps that will get me fixed. Maybe the fan will need to be replaced also.

    I am considering doing the Toyota repair manual subscription and downloading all of the Prius-relevant manuals. As per the above linked thread, there is battery fan troubleshooting info.
     
    j12piprius and bisco like this.
  5. thomas4782

    thomas4782 Junior Member

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    Ok, I decided to bypass the connector and avoid the hassle of pulling the terminals out and re-soldering onto fresh wire. I went ahead and got some butt splices and connected everything up - the fan works now! Air flow seems pretty strong too!

    However, a few minutes after turning the car back on, the engine cranked on to charge the battery up and it threw a P3012 error - Block 2 becomes weak! I checked the live data, and it looks like the voltage for Block 2 is ~0.5V higher than the rest. I assume this is another module gone bad, and the lowered capacity is causing the weak module to charge much more quickly.

    I had purchased 4 modules from a seller on e-bay, and it looks like 3/4 of them have now failed, despite them being sold as good and working. The first 2 failed during the module balancing process. Unfortunately the seller is no longer a registered member of eBay, so I have no way to contact him and get a refund.

    I am most likely going to purchase 2 modules; One to replace the current failed one, and a second to replace the last module of the 4 I was sold as "good", as I'm sure it will fail soon...
     
  6. stockdaddy

    stockdaddy Member

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    To throw the error, the voltage should be 1.2V less than the other cells. When you say live data, you mean while you are driving or just when you started it up parked?

    I think it be best to confirm a low voltage before you do the replacement.
     
  7. thomas4782

    thomas4782 Junior Member

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    So I pulled the battery out, cracked it open and measured the resting voltages. Then I rigged up a car headlamp to some clips, and measured each module under load. My results:

    Code:
    Cell #       Resting V               Load V
    1            7.52                    7.43
    2            7.58                    7.48
    3            7.55                    7.48
    4            7.56                    7.49
    5            7.57                    7.49
    6            7.58                    7.51
    7            7.57                    7.64
    8            7.57                    7.48
    9            7.66                    7.62
    10            7.57                    7.49
    11            7.58                    7.53
    12            7.58                    7.49
    13            7.64                    7.55
    14            7.63                    7.48
    15            7.54                    7.47
    16            7.64                    7.49
    17            7.57                    7.58
    18            7.58                    7.48
    19            7.55                    7.52
    20            7.66                    7.58
    21            7.58                    7.53
    22            7.66                    7.58
    23            7.59                    7.54
    24            7.63                    7.57
    25            7.66                    7.61
    26            7.57                    7.48
    27            7.60                    7.51
    28            7.44                    7.36
    
    The error that I read on the MiniVCI said that Block 2 becomes weak. This correlated with Block 2 reading 0.5V higher than the rest of the blocks in the MiniVCI software. Am I correct in assuming that, if a module has less capacity, it will charge faster, and that after a given charge time (ex 10min), that module will have a higher voltage compared to the rest of the modules?

    Also, modules are counted from the ECU side right? So Module #1 will be the closest to the control circuitry? When the MiniVCI says Block 2, does that mean modules #3 and #4? Looking at my numbers, neither of those look particularly fishy.

    Module #28 has a low resting and load voltage however, but if I am correct in assuming that will be classified under Block 14, why didn't I get a MiniVCI code about Block 14?

    Looks like the voltages are all over the place, perhaps all I need is to wire them up in parallel again to even them out??

    Thanks for all the help you all have given me, and big thanks to anyone who can help me shed some light on this issue.
     
  8. strawbrad

    strawbrad http://minnesotahybridbatteries.com

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    Yes, the weak modules charge and discharge much faster than good strong modules. My favorite charge and discharge test is.


    Nope and yes. The count starts opposite the ecu. A block is two modules.

    Paralleling modules does not bring them to the same SOC. It will match their voltages, but that is just surface charge.
     
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