Hybrid Auto Charger not working

Finally got around to installing my new Hybrid battery charger from Hybrid Automotive in my 2007. Pretty easy & straight forward wiring install.

After installation I did the first test just hook up the charger to its dongle and no interlock and it looks ok shows 250 volts and 0 amps on there charger display but I have no battery fan. The fan is on in the charger but no hybrid battery fan..
No 12 volts from there charger to there fan control box input.

Install directions say all the fans should be running from the get go.

Then I installed the interlock to see if it will charge and it does. Shows 222 volts and .337 Ma's which is correct but still no battery fan. No 12 volts form the charger.

Fan control box is really easy 4 wires. I took a picture of it. Its hooked up correctly. My luck..... looks like I got a defective unit.

 

Hi Bisco
I have not seen any other Hybrid Automotive installation on PC. May have missed one. Was going to post mine but the charger doesn't work.

There quite adamant in there instructions about making sure all the fans are running the second you turn it on. It looks like its charging but I don't want to continue the charging without the hybrid battery box cooling fan running so kinda stuck. Have to wait till tomorrow to see what they say. Thanks.

 

Thank you very much. Exactly what I was hoping to hear.

There's no fan start up delay right?....fan should come on immediately as the instructions say right?

In charge mode my charger numbers look exactly like yours exact numbers so I know its charging Hi Volt is ok just no 12 volts to fan.
I opened the charger and found a fuse for the hi volt supply but no fuse for the 12 volt supply.

Today I'm going to disconnect the charger lead that goes to the little black fan control box and see if the 12 comes up. Check that control box circuit. Its quite clear how to hook it up. Easy.

Frustrating to go through all that work and have it not work.

 

There's a test in the instructions that has you hook the charger to the dongle with the Orange battery Interlock REMOVED. That test should show the charger output on the face of the charger at 250 volts and 0 current draw and all fans should be on. It did but no battery fan.The instructions state if fan is pulsing or not running do not proceed so maybe the instructions are wrong. I will wait but thanks very much for your time Foto.

 

Found my issue. Really bad quality control. The main 12 volt input wire to the fan control board was never even soldered. I hooked it back up today with the intent to see if that fan control board was blown and started probing the 12 volt input from the charger and my probe knocked the 12 volt wire right out of the hole it was sitting in. Looks like the wire was cut flush and just sitting in the hole not even soldered. I can see through the hole and see no solder. Ridiculous.

Pretty pissed. Have to take this box to work tomorrow and fix it. Probably the whole board needs to be resoldered. Meanwhile driving around with the car tore up. Whats annoying is they knew I was a Priuschat member when I bought it and I would think they would make sure the system they sent me worked. Nope. Never even plugged it in.

 

I did call them. And have emailed them. Holiday weekend. No answer. I did get a robo email.

The difficulty is its freakin' hot as hell here and its alot of work to install this system. I was ok with that if it worked but when it didn't I started second guessing myself and then had to take covers back off to check my wiring only to find that my wiring was fine. Added hours to the install.
And blew my day and my only window to have the car down for 24 hours while it charges. Very frustrating.

It could have been avoided it they checked the unit between Malaysia and my house.

 

Awesome Foto. Thanks man for all your help.

I took the fan control box into work today and repaired it. Just something weird happened along the way I guess to this box. Apparently the 12 volt wire pair that goes from the charger to the fan control box where they are soldered to the board the tech then trimmed them and on one lead trimmed it so hard that the entire solder land was cut off. Caught it perfectly trimmed it off clean at the pad with some new super sharp Xceleite nippers I bet. Very strange never seen that before. Not sure how the tech didn't notice that. Having a bad day I guess.
I trimmed the wires back and resoldered the whole board and bench tested it with a 12 volt ps and it worked.

Took it home and its now in my car charging as we speak. All fans running. They seem like nice folks. And have responded quite nicely to my issues. It was more expedient for me to fix it myself. Been a bench tech for about 40 years. I did request a small reimbursement to cover my time. We'll see how that goes.

One of the main reasons I liked this whole system was it made me go where I needed to go which was the main battery relay to hook up some power leads. Going to use these later on with a 200 volt input Inverter for Hurricane use. Lots of info on the Converdant Inverters. Techno Fandom has a good write up on the Converdants. I used some very high quality dc power cable ox free. Very soft 6 gauge wire. I soldered some lugs onto the leads and right now there laying in the same storage hole as the charger dongle ready to go.

Pic #126 shows the chopped pad hole.
Pic#131 is my re-work.

Thanks!!

 

Hi Jeff I sent you an email. Its all good running fine thanks for all your help.
Ray