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2016 500e Dead HV Battery

1214 Views 54 Replies 4 Participants Last post by  Electric Tire Shredder
I've been following posts on the high voltage battery issues. I purchased a 2016 500e from a used car dealer about a month ago. It came without keys. I paid a diagnostic shop to install a new body control module (from the local Fiat dealer) and program two keys. The 12 volt battery was dry of electrolyte, which seemed to indicate a possible drained HV battery. I replaced the 12 volt battery with a new one. When I test the connections in the motor compartment for voltage (under a metal plate secured by three torx screws), I get 5 volts. I've purchased a Chromebook and Konwei plug and downloaded Alfaobd.com. I'm wa
iting for a yellow adapter.
Meanwhile, there's no contactor noise upon turning the key. The dash says "not ready."
Plugging in an OEM 110v charging cord get occasional "goalposts" but no steady charge indication.
I'm hoping to make this nice looking 2016 500e with 56k miles a runner, but so far I'm not hopeful.
I've followed the troubleshooting hints and searched youtube and googled for ideas.
Pleasant suggestions?
41 - 55 of 55 Posts
Reading faults for: Electric Vehicle Control Unit (EVCU)
___
Faults reported:
2023/05/22 22:22:02.551
Faults found.
B23B0
P167B
Error code: B23B0
BPCM Fault

Last test completed unsuccessfully
Error present
Failure warning lamp 'ON': Not requested
Error counter: 40
Test Failed: Yes
Test Failed This Monitoring Cycle: Yes
Pending DTC
Confirmed DTC
Test Not Completed This Monitoring Cycle: No
Warning Indicator Requested: No
Environment at first detection:
___
Operating time: 498644 min
Time since Key-On: 0 sec
Startups counter: 1
APM Status: Off
Direct Battery Sense Voltage: 11.47 V
Commanded 12V Setpoint Voltage: 14.20 V
Intelligent Battery Sensor: Measured Voltage: 29493.00 mA
Intelligent Battery Sensor: Temperature: 18 Deg.C
Intelligent Battery Sensor: Error in NVM Data: 100 %
Hybrid System State: Initialize Shutdown
Ignition Status: Run
Propulsion Ready Status: Not set
PRND Status: No selection active
Park Pawl Position Sensor Counts: 0
Distance Traveled with Light ON: 90305 km
Estimated Range: 255 km
High Voltage Battery State of Charge: 50.20 %
Ambient Air Temperature: 18 Deg.C
Motor Temperature: 19 Deg.C
Inverter Temp: 18 Deg.C
Maximum Battery Cell Temperature: 25 Deg.C
Minimum Battery Cell Temperature: 25 Deg.C
Maximum Battery Cell Voltage: 0.00 V
Minimum Battery Cell Voltage: 0.00 V
Charging System Status: Wait For Charge Ready
Secure Connection: Unplugged
Contactor Closed: Off
Battery Contactor Commanded PWM: 69.80 %
High Voltage Battery Pack Voltage: 0 V
High Voltage Battery Current: 511.50 A
Motor Torque Command: 0 Nm
Motor Torque Actual: 0 Nm
Driver Intended total brake torque: 0.00 Nm
Motor Speed: 0 rpm
Vehicle speed: 0.00 km/h
Accelerator pedal sensor 1: 1.01 V
Accelerator pedal sensor 2: 0.50 V
Brake Status: Not pressed
Actual Inverter State: Precharge
Commanded Inverter State: Standby
Environment at last detection:
__
Operating time: 498644 min
Time since Key-On: 0 sec
Startups counter: 1
APM Status: Off
Direct Battery Sense Voltage: 11.47 V
Commanded 12V Setpoint Voltage: 14.20 V
Intelligent Battery Sensor: Measured Voltage: 29493.00 mA
Intelligent Battery Sensor: Temperature: 18 Deg.C
Intelligent Battery Sensor: Error in NVM Data: 100 %
Hybrid System State: Initialize Shutdown
Ignition Status: Run
Propulsion Ready Status: Not set
PRND Status: No selection active
Park Pawl Position Sensor Counts: 0
Distance Traveled with Light ON: 90305 km
Estimated Range: 255 km
High Voltage Battery State of Charge: 50.20 %
Ambient Air Temperature: 18 Deg.C
Motor Temperature: 19 Deg.C
Inverter Temp: 18 Deg.C
Maximum Battery Cell Temperature: 25 Deg.C
Minimum Battery Cell Temperature: 25 Deg.C
Maximum Battery Cell Voltage: 0.00 V
Minimum Battery Cell Voltage: 0.00 V
Charging System Status: Wait For Charge Ready
Secure Connection: Unplugged
Contactor Closed: Off
Battery Contactor Commanded PWM: 69.80 %
High Voltage Battery Pack Voltage: 0 V
High Voltage Battery Current: 511.50 A
Motor Torque Command: 0 Nm
Motor Torque Actual: 0 Nm
Driver Intended total brake torque: 0.00 Nm
Motor Speed: 0 rpm
Vehicle speed: 0.00 km/h
Accelerator pedal sensor 1: 1.01 V
Accelerator pedal sensor 2: 0.50 V
Brake Status: Not pressed
Actual Inverter State: Precharge
Commanded Inverter State: Standby
Error code: P167B
Controlled System Shutdown

Last test completed unsuccessfully
Error present
Failure warning lamp 'ON': Requested
___
'Clear fault codes' command sent
___
Reading faults for: Electric Vehicle Control Unit (EVCU)
___
Faults reported:
2023/05/22 22:22:49.950
No faults reported by the unit.
___
Reading faults for: Electric Vehicle Control Unit (EVCU)
___
Faults reported:
2023/05/22 22:23:57.572
Faults found.
B23B0
P167B
Error code: B23B0
BPCM Fault

Last test completed unsuccessfully
Error present
Failure warning lamp 'ON': Not requested
___
'Clear fault codes' command sent
___
Reading faults for: Electric Vehicle Control Unit (EVCU)
___
Faults reported:
2023/05/22 22:24:08.110
No faults reported by the unit.
___
Reading faults for: Electric Vehicle Control Unit (EVCU)
___
Faults reported:
2023/05/22 22:25:05.492
Faults found.
B23B0
P167B
___
'Clear fault codes' command sent
___
Reading faults for: Electric Vehicle Control Unit (EVCU)
___
Faults reported:
2023/05/22 22:25:15.082
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3
Looks like your starter battery might be getting low: "Direct Battery Sense Voltage: 11.47 V"

& it looks like your HV pack is dead: "Power Up SOC at time of Fault: 0.00 %"

& there was no missing digit on the SUPER-low average mV:
"Maximum Battery Cell Voltage: 3680 mV
Minimum Battery Cell Voltage: 3157 mV
Average Battery Cell Voltage: 798 mV"

Obviously it's impossible for the minimum to be higher than the average, so one of those numbers isn't current. Please try to connect to the BPCM like this:
Product Rectangle Font Line Screenshot

Font Slope Screenshot Parallel Rectangle

& then check the app's actual readout, scrolling down until you see this, minus the red box I added:
Font Number Parallel Document Circle
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In case you do have to open the HV pack to recharge the cells, I'm trying to figure out how to determine why the car died in the first place.

It's possible it was simply parked unplugged for too long (click here), in which case it should "only" need individual cell recharging. Or maybe after that you "just" need to install a used OnBoard Charger if the old one was fried by nearby lightning, or the Body Computer you already replaced was blown by the original owner losing both OEM keys & using a non-transponder copy*.

However, if it was the BPCM, it's repairable, but it's inside the pack, so it would really suck to have to take it apart again. You seem to have the same persistent code B23B0 as the well-detailed @fiatatat BPCM failure thread (click here).

I copy/pasted your first log above into a .txt file (attached below) & searched it for the other @fiatatat codes P0ABB, P1A21, & P0AA2, and they don't appear to be present, but that may not mean it's not a bad BPCM.

* Excellent key details by @ga2500ev if you click here & wait for it to go to post #8.

Attachments

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Just making sure - this is the EVCU log? You are unable connect to BPCM? BPCM log is separate, and gives you a lot of information about cells.
  • Helpful
Reactions: 1
I have the alfaobd $49 app. But when I connect to the BPCM and try to read System Status, I don't get the individual cells status.
The BPCM log doesn't seem very complete compared to the example posted in #42 above.
The BPCM log doesn't seem very complete compared to the example posted in #42 above.
...and now multiple attempts to connect to the BPCM aren't working.
AlfaOBD auto-saves the logs, so have you tried opening the BPCM log on a computer?

If your app is on a phone or tablet, plug it into the computer's USB, & the files show if you follow this "map":
Font Screenshot Technology Electronic device Multimedia
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AlfaOBD auto-saves the logs, so have you tried opening the BPCM log on a computer?

If your app is on a phone or tablet, plug it into the computer's USB, & the files show if you follow this "map":
View attachment 115515
I connected my Galaxy tablet to my ASUS PC. The log didn't include the data yours shows. It was brief.
I connected my Galaxy tablet to my ASUS PC. The log didn't include the data yours shows. It was brief.
I’m
Actually, it is not brief bit I don’t see cell data so far..
Rename BPCM_Info.log to BPCM_Info.txt and paste here as an attachment.
  • Helpful
Reactions: 1
If your contactors aren't closing, I don't see how you will be able to get cell data without taking the pack apart.
I'd been thinking that too, but the contactors only connect/disconnect the full ~400V power. That doesn't mean the individual cell data signals are also disconnected.

In any case, there's 59.3KB of data in the BPCM log file. My own 1-scan files with individual cell voltages included are sometimes only 32k, so it seems like there might be at least one full scan saved there.

Rename BPCM_Info.log to BPCM_Info.txt and paste here as an attachment.
That's a neat trick!

So @Curtis should right-click on the BPCM file, select "Rename", change .log to .txt, hit "Enter", & then tell it "Yes"? (when it asks if you're sure since it "might become unusable")
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