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Charging Issues - System Malfunction

Discussion in 'Gen 1 Prius Plug-in 2012-2015' started by ZackWeeh, Mar 19, 2024.

  1. ZackWeeh

    ZackWeeh New Member

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    Hello everyone,

    I purchased a Prius Plugin 2012 half year ago, and I've been facing some issues on charging. I'm reaching out to seek advice and gather insights regarding this problem.

    During the first week of owning the car, I didn't encounter any issues while charging. I used the aftermarket charging cable that came with the PIP, as well as an 220V wall mount EV charger at my home with a Type 2 to Type 1 adapter, and everything worked fine.

    However, after a week of normal usage, I had an incident when I arrived home and plugged in the EV charger. Initially, the charging socket orange LED on the car lit up, and the EV charger's relay clicked, indicating that charging had begun. But after a second, the relay clicked again, signifying that charging had stopped. At this point, the orange LED on the car flashed ten times before turning off. When I pressed the Power button in the car, the dashboard displayed the error message: "CHARGE RESULT: CHARGE STOPPED DUE TO SYSTEM MALFUNCTION." The error code shown was P3203. After clearing the error code, the car operated normally, including regenerative braking.

    Over the next two months, I tried various methods of charging at home, but I consistently encountered the System Malfunction P3203 error as above. I noticed that if I approached the car without the key fob, causing the interior lights not to turn on, the charging process would work normally.

    Additionally, if I parked the car after I drove home and immediately plugged in the charger, the P3203 error would occur. I had to wait for the battery cooling fan at the back to stop before being able to start charging.

    I have already replaced the 12V battery from the dealer and had it checked by the dealer. However, they informed me that without the original Toyota charging cable, they couldn't diagnose the issue. The cost of purchasing a Toyota charging cable from the dealer is £700, which seems unreasonable to me, so I haven't bought it and nothing checked by the dealer.

    My EV charger, a PodPoint Solo, is located around 30 meters away from the main switch.

    I have inspected the charging socket on the car and all the pins are fine. I believe it's not the source of the problem.

    Now for a successful charge, I need to ensure that the car is locked, lights are off and the fan is not running inside the car. Even if I plugged the charging cable and both the car and EV charger's charging lights are on, it doesn't mean that charging is in progress. The first three hours are spent waiting charge nothing. During this waiting period, if I unlock the car door, the P3203 error appears. After approximately three hours, the charging process eventally begins. If I press the Power button at that moment, dashboard shows the charging time remaining. Since the EV charger operates at 220V, it takes around 1.5 hours to complete charging. In total, I need approximately 5 hours to charge my PIP.

    I would appreciate any suggestions or recommendations on how to proceed with troubleshooting this issue. Should I consider replacing any charging components in the car? Any advice or experiences shared would be greatly appreciated.

    Thank you all for your time and assistance.
    Error.jpg Charge.jpg
     
  2. vvillovv

    vvillovv Senior Member

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    A few question will undoubtedly be asked by myself and others, each will probably have different goals in mind when asked, so do your best to answer what you can.,
    How did you get the dtc code P3203 ?

    If you Gen 3 2012 Prius Plug-in UK model is waiting until the traction battery fans stop, and now is waiting several hours after being plugged in to start charging, my first thought is that the traction battery temps are getting higher than normal.
    One way of checking that is using the DrPrius app Dr. Prius App with an ODB2 bluetooth adapter.

    By the way, some of your terminology is somewhat confusing to US readers, especially if only read once or skimmed through, since the US standard is 120 volts at most home outlets and 220 volts uses different plug and socket combinations.
    So more info about which EVSE you are using and at which switch setting ( 120 volt or 220 volt ) you use most of the time, and if the cars behavior is different when using your two different EVSEs
    or when switching voltage settings on the switchable EVSE.

    Mostly, does exactly the same behavior happen when your switchable EVSE is set at the 120 volt switch than plugged into the car.
     
  3. ZackWeeh

    ZackWeeh New Member

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    Thanks vvillovv, I try to make it clear.

    I got the error code from an OBD2 bluetooth scanner on iphone, which is not recognized by DR Prius. According to the OBD2 scanner's app, P3203 is a problem on the car charger circuit. I just ordered a Dr Prius supported OBD2 for the traction bettery check.

    The home plug charging cable and the wall mount EVSE are both 230 volts which is the UK home power supply standard. I took photos of them and posted below.

    Charging the car with both EVSEs will have the same problem and same error code.

    If the car is fully charged, it will show having 13.8 miles on EV.




     
  4. vvillovv

    vvillovv Senior Member

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    I can finally see the pics you attached to your OP,
    so when you took the second pic you were charging at Type 1 120 volts, yes?
    I remember with my 2014 Plug-in that Type 2 220 volt charging took about 2 hours to fully charge the battery form 0% EV / State Of Charge to 100% SOC.
    DrPrius is a great app for Toyota hybrid battery stats, I also use the Car Scanner app for the engine related info. Car Scanner ELM OBD2 – The best car OBD2 diagnostic solution for iOS and Android in your pocket!

    Screenshots of DrPrius are all over this forum. If you have a question about what you are looking at with the app, a screenshot always helps along with a description how you were driving ( edit: charging or waiting to charge ) the car when you took the pic. plus anything else you think of to add.

    I'd check the hybrid battery cooling air inlet and fans to see if they need cleaning, while you wait for the OBD2 adapter to arrive.

    I'm also not finding anything related to the 2012 Plugin with a Diagnostic Trouble Code / DTC P3203. I see one here at priuschat related to a 2007 Prius, but I think that might be misleading after reading it and some of the other links for different model Toyota cars.
     
    #4 vvillovv, Mar 21, 2024
    Last edited: Mar 21, 2024
  5. ZackWeeh

    ZackWeeh New Member

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    Thanks for you advice vvillovv.

    The Type 2 to Type 1 adapter is just a very simple rewire hub. Nothing to do with the voltage change. So the second pic in the #1 post is using 230V to charge.
    [​IMG]

    I cleaned the 2 traction battery fans and the passenger seat air inlet. No noticeable blockage.
     
  6. vvillovv

    vvillovv Senior Member

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    If your issue really is about the traction batteries temp being to high to start charging when you plug in, one thing you can try to help get an idea or two, after charge has finished to 100% SOC, let the car sit for at least a few hours or overnight. Than, take the car out for a short drive, using about 10% of the battery or about 90% SOC. Than plug in and see if the charge starts when plugged in.

    Also, if you haven't checked already, just in case, double check that somehow a charging schedule hasn't been programmed into the charge settings.
     
  7. ZackWeeh

    ZackWeeh New Member

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    I got the OBD2 finally. Below is the screenshot just after a 5 miles ride in HV mode and before plugging in the charger. Seems the traction battery temperture is OK. Then I plugged the charger it showed the System Malfunction message and error P3203 again.

    The charging timer is not active.


    WhatsApp 圖片2024-03-2322.01.10_ec4f0d35.jpg WhatsApp 圖片2024-03-2322.01.10_2cf97c17.jpg
     
  8. vvillovv

    vvillovv Senior Member

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    So, you went 5 miles in HV, DrPrius shows SOC at 22% , you say battery temps look OK to you.

    Just sayin, when you plugged in and got the dtc - what SOC / EV miles - was the car showing?

    Do you get the same dtc when you plugin with 90% SOC / 10 EV mile of range?

    Your 2012 PiP still showing 13 EV miles of range?
     
  9. ZackWeeh

    ZackWeeh New Member

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    I know nothing about PIP battery running tempreature and SOC. I am more familiar with my phone battery temperature. :)
    I collected some battery data of my today driving which showed below. Sorry many pics makes this post so long.

    Here is yesterday charging time. I plugged the Prius to the charger at 17:30, red arrow on below picture. The car actually start drawing current at 22:30, green arrow. The charger plugged but idling time become even longer. Maybe something is getting worse.
    IMG-20240325-WA0010.jpg

     

    Attached Files:

  10. vvillovv

    vvillovv Senior Member

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    Sorry I didn't catch these sooner......
    These pics didn't show up until you made your second post in this thread and your post count was than 5 posts.
    This pic of your MID message is saying there is an issue with the charging system.
    What that issue is I still don't have a clue yet. I can't find anything related to your 2012 Plug-in with a P3203 code. But at least I'm now focused on the charging system error.

    Two things I've noticed. DrPrius is still not working in your 2012 Plugin correctly, I believe. My first clue was the voltage and state of charge don't raise and fall together like they should. The graphs are not showing the right cell / module count either. Your car has 4 banks of lithium cells ( maybe 22 cells per bank but I don't have the exact number of cells per bank ).
    Did the adapter you mentioned you were going to get arrive yet?

    Don't worry that your posts might be long, I can only imagine how frustrating it must be for you to try to figure out what is wrong with the data you are seeing.

    With my understanding of DrPrius screens, it looks all wrong to me. Which begs the question, is the dtc P3202 the right error code and if it is what does it point to in the charging system.

    Here is a random DrPrius screenshot from my 2017 prime which has a very similar battery configuration to the 2012 plug-in , so you can see what the screens are supposed to look like.
    charged to 100 % - 6jul2023-DrPrius-100percent-P1020522.jpg
    discharge to 0% - 6jul2023-DrPrius-0-percent-P1020544.jpg
     
  11. vvillovv

    vvillovv Senior Member

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    Looking through the 2013 Plug-in owners manual pdf file
    https://attachments.priuschat.com/attachment-files/2015/08/80039_MY13_Prius_Plug_in_QRG.pdf

    gave me two ideas you might want to try.

    After plugging in get in the car and turn it on ( Press the ON button twice with your foot off the brake ) and if you see anything on the MID indicating why it's not charging, please take a pic and post it.

    Another thing you can try is to plug in, unplug, than plug in again. - In the Gen 4 this overrides the scheduled charge time ( if scheduling has been programmed in ) and starts charging immediately. - rinse and repeat to see if you can get charging to start sooner than the 5 hour wait ( as posted above ).
     
  12. ZackWeeh

    ZackWeeh New Member

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    The OBD2 I bought is this one Car & Motorcycle Code Reader Check Engine Fault OBD2 Scanner For IOS Android | eBay
    The Dr Prius screen for the cells of my car is very simular on both iPhone or Android.

    I took a video of the charging error. The first shot is at the charging socket. Second shot is at the battery bay. Then follow by the error message on the dashboard screen. I hope the relay sounds in the video can give a clue.


    About the chinging timer, I am quite sure it is not activated. If activated, the orange LED at the charging socket will be off after a few second instead of 10 blinks error. But I also tried to plug and replug the socket. This time I discovered something new. After 3 consecutice plug and replug, the orange charging LED did not blink 10 times. It became long lit that show the car was charging. I leave it there for 10 minutes. Then I turn on the car I found it really started charging!!
    WhatsApp 圖片2024-03-2720.11.03_4710929a.jpg

    WhatsApp 圖片2024-03-2719.57.06_1b2391d6.jpg


    The charging finished within 2 hours. I know the error will happen again next time. How strange.
     
    vvillovv likes this.
  13. vvillovv

    vvillovv Senior Member

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    Looks like we got lucky with the 3 plugin and replugin dance starting the car charging. Yes, I heard the sound, but it's hard for me to put it in context of where the sound might be coming from just looking at the back of the battery. Do you think that sound is maybe coming from the front of the battery just behind the rear seat, or maybe from under the rear seat cushion, both on the (uk) driver side? If that sound is not coming from either of those locations getting as close to where you think it might be could be helpful.

    Can the DrPrius app clear the code it's showing? If it can clear the colde, does the code come back?
    I'm also concerned aboujt the 1st message on the MID in the video, the one before the charging has stopped message. Tnat message along with the sound you are concerned about is the reason I'd like to get an idea of where that sound is coming from.

    I checked some DrPrius videos and now see that your DrPrius screenshots are good and show the way DrPrius is meant to show the graphs for the Gen 3 Prius Plugin.