HCH Battery is dying :(

[Jdesign]

Originally Posted by S Keith

I find that very concerning. Are you 100% certain the battery fan is being driven?

Are you doing the charging with the IPU lid closed or open?

https://www.dropbox.com/s/k9tgm6qvl2...ector.jpg?dl=0

14-6
6-13
13-4
4-12
1-7
7-2
2-8
8-3
3-9
9-10

I didnt get a chance to check the codes yesterday. The car is kind of boxed in at the moment.

I am 100% sure the fan is running and pumping out air. I have both the trunk open and the IPU cover off.

Sadly I did check the voltage again this morning after the car sat since yesterday around noon (approx 20 hours) with no charge or discharge activity and the voltage dropped to from the 169 it was at to 163.

[S Keith]

Originally Posted by Jdesign

I didnt get a chance to check the codes yesterday. The car is kind of boxed in at the moment.

I am 100% sure the fan is running and pumping out air. I have both the trunk open and the IPU cover off.

Sadly I did check the voltage again this morning after the car sat since yesterday around noon (approx 20 hours) with no charge or discharge activity and the voltage dropped to from the 169 it was at to 163.

Okay, there's the problem. With the IPU cover off, you have disabled all battery cooling. Your voltage drop was due to the battery getting extremely hot.

The battery cooling system works as follows:

Battery fan blows air into trunk.
This creates low pressure in the IPU bay.
Air is drawn in from the upper deck, down through the battery, through the IPU bay and then out the fan into the trunk.

You have subjected your battery to extreme temperatures. Couple that with extended over-charging, and you have likely induced a large amount of voltage depression into the pack - what you tried to get rid of with your discharge. Hopefully, you haven't done permanent damage.

BEFORE DRIVING THE CAR, I recommend you:

1) discharge pack to 96V
2) install IPU cover
3) charge the shorter of 32 hours OR peak voltage held for 8 hours. Attempt to verify that air is being drawn in through the vents in the upper deck (you should be able to feel/hear it)
4) remove IPU cover
5) repeat 1-3

[S Keith]

(crickets chirping)

[Jdesign]

Originally Posted by S Keith

Okay, there's the problem. With the IPU cover off, you have disabled all battery cooling. Your voltage drop was due to the battery getting extremely hot.

The battery cooling system works as follows:

Battery fan blows air into trunk.
This creates low pressure in the IPU bay.
Air is drawn in from the upper deck, down through the battery, through the IPU bay and then out the fan into the trunk.

You have subjected your battery to extreme temperatures. Couple that with extended over-charging, and you have likely induced a large amount of voltage depression into the pack - what you tried to get rid of with your discharge. Hopefully, you haven't done permanent damage.

BEFORE DRIVING THE CAR, I recommend you:

1) discharge pack to 96V
2) install IPU cover
3) charge the shorter of 32 hours OR peak voltage held for 8 hours. Attempt to verify that air is being drawn in through the vents in the upper deck (you should be able to feel/hear it)
4) remove IPU cover
5) repeat 1-3

Sorry I didn't get back sooner. Other priority's took place but im back now. I will discharge to 96v and install the cover and recharge. After doing so I will I will check back. Further note, the voltage has been at 163 since we talked last without any change.

Once I do a few cycles I will connect the regular battery and drive it to see if it still throws an IMA code. If so I will check read the codes.

[S Keith]

Given the fact that it's been sitting a few days, it would be a very good time to check the tap voltages before you start the discharge.

[Jdesign]

Originally Posted by S Keith

Given the fact that it's been sitting a few days, it would be a very good time to check the tap voltages before you start the discharge.

I did as you recommended:

1) discharge pack to 96V
2) install IPU cover
3) charge the shorter of 32 hours OR peak voltage held for 8 hours. Attempt to verify that air is being drawn in through the vents in the upper deck (you should be able to feel/hear it)
4) remove IPU cover
5) repeat 1-3

Made a noticeable difference with the cover on and was able to get the pack to read a stable 181 after sitting a good 48hours.

I reconnected the reguklar battery and drove the car all weekend without issue. No IMA or CEL on. It was glorious.

Day 4 I wasnt so fortunate. I was stuck in heavy traffic and the IMA light showed its face again. (note that im driving in 30F temps too) The car has since been parked and I will take the readings from the connector per your suggestion.

You said:"There is a lead to each stick pair, i.e., you just walk the probe from one set of pins to the next."

By walking do you mean I hook up to a ground(which pin?) and then check each cell or pin and write down my voltages?

Also I appreciate everything you have helped me with up to this point, THANK YOU.

[S Keith]

Before you do anything, get the codes read.

For voltage readings, you click the dropbox link that shows you a picture of the BCM connector. You measure the 10 voltages between the 10 pin pairs and record them to XX.XX accuracy. You don't unplug it. The picture is the back of the plug.

Again, here are the pins:

14-6
6-13
13-4
4-12
1-7
7-2
2-8
8-3
3-9
9-10

As you can see, in all but one case, the 1st pin is the 2nd pin of the group above. You can take measurements by moving the probe from the first pin of the top line to the second pin of the next line... this is what I meant by "walking the probe". Your polarity will flip flop between readings, but that doesn't matter.