Rebuilt my Prius battery. Replaced a 2 module. Sorted modules inside to outside. All 28 cells tested at 7.8v. Placed back in car and installed Prolong wiring harness then hooked up the Prolong charger per instructions and it started. It went just as the procedures read. Fans on voltage wavered for a moment all looked good. The charger read 202V and .004A and has not changed in 7 hours. 2 things, 1) if all individual 28 batteries confirmed at 7.8v shouldn't it read 218.4v and 2) .004A - isn't that too low to charge anything? My fear is that it is not charging anything at this time. Any insights? <this is actually written by my husband who is trying very hard to keep my beloved Prius running for me. It threw the triangle of death and the hybrid battery error just after turning 250k. We opted to replace modules (only one was showing as bad) and try the charger. One round of whack-a-mole and then we make a bigger decision of this doesn't work>
You are correct, I'd agree that something is wrong. The last I knew, the charge rate should be around 0.350 amps, which is about 90x what you say yours is showing. Did you get the discharger also?
try using the discharger for a few minutes. Just to see if it functions correctly. That would at least verify whether its a device issue or a battery/wire harness issue (open circuit). With the charger not putting out any amperage, the possibility exists you could have an assembly problem on the battery, a connection problem with the harness, a bad harness, or a bad charger. If the discharger functions correctly then I would say the battery assembly is ok, the harness and it's connection would also be ok. That leaves only the charger to be faulty.
The charger is not pulling any current should be showing .338 which is 338 milliamps. The charger is clamped at that regulation so it charges pretty slow so not to invoke heat. So I think Ski may be right the safety plug is not installed properly. You insert it fully then flip up the handle then push the handle down till it locks. Everyone forgets the push down part. My ammeter on my charger goes crazy after a full discharge and battery voltage is very low it shows wild fluctuations between 0 amps and .338. Flips back and forth real fast. It settles in after a while when the battery voltage reaches 150 or so volts. Freaks you out first time though. You have to charge it for at least 24 hours maybe more to get full benefit.
Are you sure you connected to the right terminals at the battery. You need to connect to the battery side of the relay, not the motor side. https://cdn11.bigcommerce.com/s-l6hu360yba/product_images/uploaded_images/175a.jpg?14543599743190694813
For those that want to know....the orange safety plug provides FULL electrical continuity as soon as it's pushed in about 2mm. The fuse makes contact and full voltage is available at the battery side of the relays. Pushing it further in and rotating the handle upward merely ensure full 100% contact and locks it in place. Pushing the handle straight down does NOTHING for continuity or locking it in place, it merely installs a jumper across the safety circuit contacts so the ECU knows the safety plug is installed.
Ok but how come we see so many posters who have inserted the plug but have not Pushed the lever down and dead in the water. That’s a lot of posters that get fixed by pushing the lever down. Listen I have never been inside the pack just trying to learn so take it easy.
That's because, if you don't slide the handle to its proper position, you don't close that jumper that @TMR-JWAP described and therefore the ECU thinks the disconnect is still open.
