What would cause inverter not to charge to HV battery

With what did you replace the HV battery? If if was a rebuilt, it is likely faulty.

Also the current battery, at 204 V, is below the 40% SOC threshold above which the HV battery ECU likes to keep the voltage. You need to give the HV battery a full charge before any further attempts to start the ICE.

I don't believe there was anything wrong with the inverter or the DC/DC converter.

You can then attempt to trace the reason the ICE looses power.

 

A hv battery would not come out of a running car at 204v. You would have to ask this trustworthy guy again.

You need to determine if that hv battery is any good, it seems like it has failed modules, that's why it's measuring 204v

Since you're able to take the cover off the hv battery, are all the serial numbers on the modules similar? What's the first 4 numbers/letters on the module serial?

 

Why did you disassemble the pack?

7.3v - 7.5v would mean you have somewhat of an imbalance battery. The variance should not be that high (although it's acceptable in the parameters of the prius ecu).

I would think if the car had p0a80 and you replaced the battery, the problem lies in the battery. Not the inverter

You should check all your wiring, make sure you didn't break anything. Also check the torque of the terminal nuts, 48 inch pounds.

 

You should check your 12v battery too, make sure it's fully charged. And when running, the 12v should measure around 14v.

You went from changing the hv battery, to now an inverter. An extra diagnostic as the inverter can be bad now

If a car dies while it's running, it's usually because the 12v is not being charged by the dc/dc converter.

 

I've never had to be bold enough to directly measure the hv battery while the engine is running. If I need live data, I would safely use my miniVCI and techstream. But there should be a voltage jump if it's charging.

You should run some of the test I mentioned, as a new 12v does not mean is charged. You have to eliminate the simple things.

How did you clean the corrosion? How tight did you tighten the terminal nuts? Do you still have your old battery?

 

You'll need to charge the hv battery before you can test more. It's out of its operating range.

If the car will start,
set your parking brake,
press and hold the brake with one foot,
put the car in drive
and press the gas pedal all the way to the floor.

This will force charge the hv battery

 

When you hear the engine spinning for a dozen seconds, and then giving up with a P3190, that means the engine never produced enough power to keep running on its own. That's why there wasn't excess power to put into charging the battery; the battery was being used to spin the engine.

-Chap

 

Wow, this car has a lot of miles.

Does the car have fuel? If you're not sure, you would need to add 5 gallons for the car to register it.

If you've cranked the engine numerous times and it won't start, there maybe other issues. You would have to determine everything else you've touched is working properly.

 

Well you'll need to get that battery charged up, maybe you can ask Matt for a little help. He's at texashybridbatteries.com

He's always providing helpful ideas and troubleshooting tips.

 

A Prius can always sound like it starts and runs great for 13 seconds—because MG1 and the traction battery crank it at about 1200 rpm, not the much lower rpm conventional cars crank at. When after 13 seconds the cranking stops and P3190 registers, that does not mean the engine ever started or ran.

-Chap