P3000 code with new NexPower V2.5 battery

deoxit cleaner

 

Female connector is the same way. You can take the module out of the battery pack completely and take it apart...or use a skinney dental flosser Q tip style device and make a baking soda vinegar paste. If really bad a dielectric grease can be added

 

Deoxit is made to spray on both sets of contacts and insert the connectors together a couple of times. If you can get in there on the male pins with a qtip on not bend them or leave debris, fine. Never stick anything on the female side unless it's the exact right pin. I would not use much else as a cleaning solution.

 

did you unplug the 12 volt battery for 10 mins or clear the code first? If so and it re appeared......then maybe a new battery ECU to replace the corroded one.

 

i would say yes

 

You could have moved the jumper and shorted the module (+) and (-).
Not a very good design of the terminals of the homemade battery. No so-called "foolproofing".

Is there a voltage leak from the battery to the case? Have you checked with a voltmeter?

 

I suspect this is user error. Troubleshooting:
1: Post a top-down, high resolution picture of the entire pack with the blade tap harness laying inline with the blades (but not touching)(i.e. the harness is just laying beside the pack).

2: Verify the module with service disconnect terminals wasn't shorted.

3: Measure and report each blade's voltage.

...

It's not my product, but in general I wouldn't recommend using unfused cells that have been shorted out. High current discharge can cause the internal cell conductors to melt down, which could produce a latent failure down the road (e.g. if a compromised internal insulator subsequently breaks down). Jack might offer different guidance², but in general I would disregard it in the abundance of caution.

Regardless, you might not be able to salvage that pack because it appears some of the threaded posts no longer exist. If you're up for it, I'll pay you whatever you paid for the sodium pack, plus shipping, plus $500 if you ship it to me. Jack of course won't like this, but that's not really something he can do anything about (due to first sale doctrine, unless you signed an NDA, in which case my offer is void). Send me a PM if you're interested (and if I get banned for posting this, send it to my reddit handle: redditmudder).

...

²FYI: Per the guidance on NexPower's FAQ, Jack is likely to tell you that I am "not a battery expert":

For the record, the only factual claim Jack makes here is "<mudder> doesn't own a Prius". For example, Jack's claim that an LiBCM customer's cells "puffed up" is entirely false. Jack is likely referring to a pending customer who purchased Samsung modules from a 3rd party, but does not yet have any LiBCM hardware. Jack's/NexPower's claims are textbook defamation per se, but I won't bore anyone with the legal details here. We all know how that went last time, so I guess I'll choose a different venue.

 

Yeah, this could have been an "off-by-one" error, which would directly short any blade whose terminals were shorted by the harness busbars. After looking at your pictures again, it appears you didn't place the blade voltage measuring harness on the same terminal as the right-most high current cables, which would cause the off-by-one short circuits you observed on several blades.

Glad you're ok... fortunately, you were probably dealing with low voltage, high current. Otherwise you might be blind and/or deaf and/or dead. High voltage high current shorts are no joke.

 

Am off-by-one error is just as possible and just as bad with an original pack. It's just something the person doing the work has to be careful to avoid.