error P0A0D after rebuild.. saftey plug seated correctly, other codes present

I know nothing about this issue or if this would cause it, but is there any chance you installed a module backwards?

 

1. Checked that you've actually grounded the battery pack, bolt it down to the car's body.
2. The orange disconnect, slide it up and down a few times. I've heard of this error happening and sliding it up and down a few times usually helps fix the problem.

 

grounded the battery pack, ?????

 

If it goes into limp mode, it won't have much power. I'm thinking the hv battery is causing your issues

 

Yes it sounds strange, that pack needs to be grounded to work. If you don't bolt it down, it won't work

 

An electrical ground to the body frame ?

 

I really don't know how to explain it, just know if it's not bolted down to the metal, it doesn't work

 

I’m guessing a physical support connection. Never an elec ground from the HV. 500 Volts to ground? A grand fire.

 

The HV battery CASE is bolted to the body of the car. Therefore, the CASE is grounded to the car body, just like the 12v negative. The HV components are NOT. The wire shielding inside the HV cables is electrically connected to the CASE where they enter the relay section of the HV battery, therefore the armor shielding is also grounded.

 

Any chance the small electrical plug is not connected at the bottom of the safety plug?

Of the three wires that are connected at the rear left corner of the HV battery, the smallest one is used for the safety disconnect. The receptacle on top turns into a wire that is only a few inches long and merely goes to the lower portion of the safety disconnect where it plugs into another small receptacle.

The other end of this second receptacle has contacts that are shorted together when the safety disconnect is pushed downward to "click". If that short wire is not plugged in, the system thinks the safety disconnect is not inserted.

Look at the video in post 2 of this thread. You can see the wire in the first several seconds of the video. Its at the bottom left corner of the disconnect receptacle.

Red Triangle and P3009-526 | PriusChat

If it is plugged in, there's always the possibility that one of the pins is bent or something and not making contact.

 

DTC P0A0D points to a safety interlock problem. Either the orange traction battery interlock has a problem or the inverter cover interlock has a problem.

DTC P0AC0 points to a problem with the traction battery current sensor, which measures current on the negative traction battery cable.

 

On the side of the battery pack that has all the voltage sensing wires, the long orange cable at the bottom of the sensor harness is the one that passes through the current sensor and then connects to the battery side of one relay. The opposite end of that cable connects to the negative terminal of the module closest to the battery electronics (module 28). That current sensor also has a small electrical plug about the same size as the one at the safety interlock. Sometimes they just don't fully click into place. You're right, probably worth popping it open and checking every connector.

 

The traction battery ECU needs a connection to ground, which probably is via the case.

1. The traction battery nominal voltage is 201.6V (28 modules * 7.2V)
2. That voltage is raised up to ~500VAC by the inverter.
3. It is true that the high voltage is isolated from ground.