warning lights on 2007 gen2 with nexcell hv pack

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by A.J. Tarnas, Oct 5, 2023.

  1. A.J. Tarnas

    A.J. Tarnas Junior Member

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    IMG_3289.jpeg IMG_3288.jpeg IMG_3287.jpeg i've got a friend who just bought a 2007 gen2 200k miles with, apparently, a nexcell / projectlithium / dr prius high voltage battery pack installed. the friend called me last night about a problem, and i don't have all the information, but i wanted to get the ball rolling here anyway.

    friend took it to a toyota dealer. neither friend nor dealer seem to understand the nexcell battery angle and their techstream report recommended hv battery replacement.

    attached are three images of the report. major error appears to be block 2 in hv pack is close to empty at 14.5v (2.9v per cell * 5 cells in this lithium-iron-phosphate / LFP situation) versus rest of blocks near 16v.

    my recommendation was to inspect and clean 12v terminals, replace 12v if old, disconnect and reconnect. then clean hv battery fan, which dealer found to be clogged. check oil for low level. and then attempt to drive car as normal.

    my best guess is that there is a fault in block 2 of the nexcell and the in-block bms is doing something that the pack bms doesnt like. i don't know yet if friend has v1 or v2 nexcell.

    @PriusCamper this car is located within an hour or two of your location.
     
    #1 A.J. Tarnas, Oct 5, 2023
  2. PriusCamper

    PriusCamper Senior Member

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    Ok, thanks for the heads up and super thorough documentation. I'll let Jack know and we'll work with them to figure it out... When Project Lithium first started selling they offered a warranty transfer to new owner for $100 fee, but that immediately proved to be way too problematic because a new owner doesn't really understand what previous owner signed up for, especially when it comes to tracking use/time that first symptoms showed up. However, as always, Project Lithium will figure out a way to make this right and will likely be generous with keeping costs down. How do I get in touch with the new owner? Also ask them to contact Project Lithium...
     
    #2 PriusCamper, Oct 5, 2023
    Last edited: Oct 5, 2023
    ColoradoCrow, A.J. Tarnas and bisco like this.
  3. A.J. Tarnas

    A.J. Tarnas Junior Member

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    i'll connect them to you next chance i get. (my friend isn't the best long-distance communicator, but i know they'll be motivated to fix this.)
     
    #2 A.J. Tarnas, Oct 6, 2023
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