I Think My Project Lithium Battery Failed After 3-days.

I've been trying to find supplies to sell a wiring kit for Nexcell buyers who own older Prius. I'd be willing to bet that with a brand new positive and negative cable and brand new voltage sensor wires & bus bars (aka Wire Frame No. 2) would eliminate all the problems with your video. But it's something I've not had any success with yet. Sourcing supplies is hard!

Jack is being very generous in shipping you a warranty replacement but I'm still pretty sure the modules are not the problem and that when the amps go up that corrosion changes the electrical signals just enough to create inaccurate readings.

For example in your video at low amp loads the voltage difference is normal. But once you put significance amps in your voltage difference is an obvious problem. It's pretty smart of you to get direct readings of the blocks with a voltmeter and compare to reading on Dr. Prius app. But I can't see those number in the video very well... It would make sense that numbers match at just a few amps when there's no voltage difference. But do those numbers still match at high amp loads, which is where the voltage difference problem is?

 

You do not want to use either of those electrical protective products. As the description says for both, those sprays are mainly for coil windings.
Those sprays should not be used to protect a PCB (board), or exposed metal.


What you want to use is "Conformal Coating".
Considering the amount you need, and the curing limitations (air cure only, no mixing), below is what I suggest:

Code:

https://www.amazon.com/MG-Chemicals-Premium-Acrylic-Conformal/dp/B07B8RY7M6/

MG Chemicals - 419D-55ML 419D Premium Acrylic Conformal Coating, 55 mL Bottle, IPC 830, UL 94V-0 (File # E203094)
Price: $12.95 
Product details
Paint Type Acrylic
Brand MG Chemicals
Color Clear
Unit Count 1.85 Fl Oz
Included Components 2 brushes
Certified Ul 94V-0 (file# E203094)
Excellent finish — smooth, homogeneous, and durable crystal Clear coat and easy to inspect — fluoresces under black light (UV light)
Protects electronics from moisture, corrosion and static discharges
Easy rework and repairs — can solder through coat or remove with MG Chemicals' thinner/cleaner, thinner 4, or conformal coating stripper
Container Size 55.0 milliliters
Dielectric Strength 1000
Ean 0779008419519 , 0779008419526
Full Cure Time 24 hours
Item Weight 1.76 ounces
Lower Temperature Rating -85 degrees_fahrenheit
Manufacturer Series Number 419D
Model Number 419D-55ML
Numeric Viscosity 100
Paint Type Acrylic
Specification Met
UNSPSC Code 31201600
UPC 779008419526 , 779008419519
Upper Temperature Rating 257 degrees_fahrenheit

Data sheet:
https://www.mgchemicals.com/downloads/tds/tds-419d-l.pdf

Don't reuse brushes.
You could use the cheap copper solder paste brushes that Home Depot sells for copper pipe soldering.
Seal the cap well, put in multiple baggies, put in a basement or the coolest place that you have, and keep out of the light (a box is good).


Good Luck!

 

Yeah... Your assumption seems pretty clear... My bias is that both nexcell packs I had this problem with had really bad corrosion and once I cleaned the ecu and replaced the wire frame no.2 with brand new all the symptoms went away. So the problems I faced and problems you face are definitely different as is clear from your lack of a P3000 at this stage.

At some point I'll understand how V1 & V2 of voltage balancing gear works and will better be able to explain it to hopefully no one because this problem has been dealt with.

Side note: Because you're a rural mail carrier using your own vehicle you're someone who knows about the overuse of mechanical brakes which is all you got below 6mph. In threads in the past we've talked about how Prius has an undersized brake system for your particular use case and I'm wondering how often you've had to replace your brakes?

 

Two years in with both prototype Gen2 and Gen3 packs and all is still well... Hope the same and many more years beyond is true for you too!

 

Thank you @TheLastMojojomo ! sorry about the issue with the original pack, we will do a full investigation and send you a report, have a good weekend ahead.

 

sure beats what's happening over at 'newpriusbatteries.com'

 

Jack actually fails to mention anything about the KNOWN corrosion problem with the ECU and the ECU harness wire terminals. I had two blades go bad within a month. Jack sent me back 2 used blades as replacement which voids his own written warranty. I have email to prove they have damage on them from him. When are the Blades he sent me wasn’t the one I needed with terminals on the opposite side as well. He states he didn’t have that in stock Then he promises to refund my money minus $50 shipping, If I send them all back. I sent them all back (packed very well) and he came out with excuses justifying giving me less than half of what I spent back. I have emails photos and video of all the corresponding and installation. This whole mess is on Jack- nothing about corrosion it in the installation instructions. I’ve posted all this on a couple Facebook groups will continue to post to protect unaware customers. This is been a huge waste of my time. I’ve ripped my car apart multiple times. tried draining, balancing his mess. This is not how you treat customers Nexpower energy, Inc. Project Lithium, whatever…✌

 

My dad was a retired Mailman. I feel your pain I also experienced catastrophic failure immediately. It’s all due to non-corrosion issues not being mentioned with the ECU and ECU wire harness. You did nothing wrong. We paid top dollar for a product that isn’t back by customer service and awareness in how they are operating their business.

 

Got any links to that? Haven't heard about it yet?

 

Jack only ships brand new modules that have been tested a one last time before they are shipped. And when you tried to replace the bad modules all kinds of things must of went wrong for you because you gave up and shipped it back for a refund. When Jack got modules back that were damaged in shipping (terminal breakage and multiple case breakage) because you didn't put them back in the boxes they were shipped in and two of the modules were discharged so badly they no longer take a charge, which isn't a symptom of the problem you faced.

Situations like this is why Jack tests every module himself before he ships them so he's certain there's nothing wrong with them.

Because of this Jack offered a partial refund of $1200 which made you so mad that you told 14K people on a Prius Facebook group that jack is a thief and ripped you off causing multiple people who were planning to order to decide not to order. So then when Jack offered you another $800 to de-escalate the situation and asked you to stop attacking NexCell on social media you rejected the offer and continue to attack him. You even bragged to me about how good you felt that people were canceling their purchase plans.

I even offered to drive to you personally and install the newest nexcell pack I've been driving in my car the past couple months to make this right... But you're more interested in picking a fight than getting your Prius running again. We're doing the best we can to help, yet you continue to be unwilling to work with us.

 

see the last few pages, plus all the other new prius batteries threads:

page-8

 

Wow...

Thanks for that link @bisco ... What a mess! Last Winter 'NewPriusBatteries' guy got so upset about my questioning the details of his doomsaying of Project Lithium he clicked "ignore" on me and he never sees my comments anymore and I guess I returned the favor by not seeing any of his posts/problems anymore? I was blissfully unaware that his business is falling apart. More proof how incredibly hard it is to be a small business startup selling hybrid car batteries.

Hope ya'll realize that and play nice if you ever buy one!

 

I requested that this post be deleted.
I paid $2250 for battery modules that failed due to ECU corrosion in 1 month. Jack is now adding the very well known ECU corrosion fact to his installation instructions as per this mess. I wasted days of my life. My car is still down torn apart, so yeah, I was pissed. The whole thing was a fiasco, I packed the blades all very well. None of them were damaged by me. y’all act like you know everything so just stop and I message you back twice Deane you never got back to me. And no, I wasn’t happy that people weren’t buying from. I was just simply saying I told Jack that I’m going to do this if you don’t honor your word.

 

What a lame forum site. You can’t edit or delete your own add whatever.