Hi Guys,
When the main switch on top of the batteries is off, and the pack has sat that way for over a minute, it is safe to touch the battery pretty much anywhere.
Gloves are a good idea if you want to be as safe as possible.
Linemen gloves with leather outer gloves and rubber inner gloves are the best, but a bit of an overkill.
As Jamesqf says, the pack can kill you, so if you are not sure what you are doing, don't fool with this.
I will be offering several versions of the grid chargers soon.
A basic 350ma with detection of pack balancing completion, and cell level temperature detection, and fan power supply.
A more advanced version with dual charge rates so the pack can be charged in one evening,which will allow charging every night for limited PHEV operation. The charger will include a fan power supply, an LCD display of battery voltage, charge current, trickle charge drop back setpoint, AH delivered, and pack temperature.
A universal charger that will be able to charge from one 7.2V subpack to 250V for full Prius pack.
In theory the concept can be expanded to charge a 400V pack, and with more current.
MIMA Honda Insight Modified Integrated Motor Assist - Building a hybrid car grid charger
Blog about the development of the grid charger and pack rebalancing(starts at the page bottom)
Schematic of 350ma basic charger
http://99mpg.com/Data/resources/down...dchargerv1.pdf
Schematic of dual rate charger
http://99mpg.com/Data/resources/down...d_charger1.pdf
Insights and Civic packs seem to respond well to this charging/balancing.
Recalibrations will usually stop, and full SOC can be used.
This will not fix shorted cells, or cells with high internal resistance, but does work very well to bring a pack that has sat for months back to life.
A great DIY project for the technically skilled as well.