Hymotion : no LED blinking, just dead?

I have a Hymotion L5 which acts like it is discharged: No blinking on dash LED unless I pull the service plug, then it blinks code 8.

When I plug 120v in, brake light flashes and fan runs. Fully charged I think.

When I start the car, the LED never comes on (like a discharged pack) And no green (full battery) flashes on the info screen.

I pull the top off. The whole pack is about 197VDC. There are hand written dates 2009 on all 14 battery modules.

Help please. Thanks, Dan.

 

I poked around some more and have additional data:

1. Harness seems to be working. I measured voltage for all 16 wires while the car is on and off/charging. While off/charging, only pin 5 has 12.4v. When on, pins 5, 6, 7, 14,15, and 16 are around 14v. Pins 9-12 are around 2.5v. The CAN bus are active? All normal?

2. The system battery is the weird part. Car off and L5 off, it reads 197.6v or 28.2v across two modules. When changing, it drops to 189v to 191.7v or 27.5vdc. Why do voltage drop when charging? Bad batteries? When the car is on, my digital multi meter can not read the voltage even when set at 1000vdc. Infinite value? It doesn't make sense. Individuals drop down to 27.6v.

I noticed something weird across the module with the service connector, the infinite reading is across this module. The rest of the modules read 27.6v. But changing the orange fuse plug makes no difference. Can the orange wires between the connector and battery modules goes bad? Physically, I do not see any corrosion or melt insulation to suspect bad wires.

This is puzzling.... Help!

 

I already did that: Pushing down on the crash sensor, pull out the service plug and check the 150 amp fuse and plug back in ( rotate up and push down), check each of the 14 modules is 14.1 VDC (no bench charge needed). There is no error code.

I purposely pull the service plug out while the system is on to be sure the system is still working and to test, making sure the LED still works. After I replaced the plug the error code goes away after a cycle of power off and on.

After a full charge over night, I power the car on and the LED is not on. No error code flashing either. What can be wrong?

 

Already did that too. Checked the fuse. Clean terminals. Disassembled the service plug, cleaned and reassembled. I even swapped service plug, same behavior.

May be I am not being very clear. I get no error code at all. I only get 8 blinks when I remove the service plug when the car is on or charging. If I put service plug back in, no LED flashing.

When I drive the car, no LED and no battery flashing green on the MFD. And mpg shows 45mpg. Is it dead? I measured the whole pack and I get 188 to 197 volts.

What voltage is a fully charged pack? And when under load?

How do I know if my DC-DC converter is an H5?
I do not get 3 blinks or any blinking at all. But it is also not on; not helping mpg.

 

I just bought the car. I think the sale man was lying when he said that it works. So I do not know the history of the system.

The label on the passenger side says mominal voltage is 188v. I opened it up and measured 197v. Plugged in the charging cable and it dropped down to 187v is that normal?

I hooked up two 60W incandescent bulbs in series and load the battery down. It starts at 196v 0.45A. After an hour, it is 189v 0.44A. Should I load it down to 179.2v to see how long and how many KwHr is in the batteries?

 

I know of two systems still working.

Last night, I drained about 420 W-Hr from the batteries in 5 hours. Then I plug it in and everything charged back up to full in 30 min.

I think it is "on" because the BMS light up like a string of red x-mas lights as soon as I opened the driver door. And if I pull the service plug, I do get 8 blinks error code.

I do not think that the system is bypassed because it is plugged into the car harness and the bypass plug is hanging by zip tie next to the DB-9 serial port in the trunk.

I wish it blinks some error code. Do I have fused contactors? Are they in the bottom of the battery box?