Comparing the same route with the air-conditioning on and off, I don't see any difference regarding MPG. That I see is battery charging is not so fast, it stays around 60% and rarely gets more. I have to shut it off to see full blue bars. Means something?
What exactly do you mean when you say 60%? Are you reading the percentage SoC with an app like Dr. Prius or Torque Pro, or are you meaning the battery graphic on the Consumption screen is 5 or 6 bars? So far it sounds like everything is normal, but depending on the answers to the above, I may add further to my answer.
Interesting. 60% should show 6 bars. 3-4 bars should indicate 47%-52% in those apps. Something does not align. In any case, I'd believe the apps. 60% is what the hybrid system aims for. In order for it to go higher (i. e. into the green bars), you would have to do a lot of braking – slowing for lights from a looong way out or going down a long descent – as examples. Also, be aware that the graphic on the consumption screen is a bit laggy, so the true SoC might not necessarily be reflected on the screen immediately. For this to be the case the OAT (outside air temperature) must be very mild in the region of 22ºC +/-. Once the OAT is getting to 27-28ºC and upward, the A/C loading increases significantly and does hit your MPGs.
We are now at the 33-35ºC region! A/C works well, no sagnificant MPG change from work>home. BTY, if I add the 2 lower bars (purple that turn to blue) total 5-6 blue bars is around 60% SOC, so I agree with you. Everything is normal.
I think that the secret is to start with a 65-70% charged battery. This helps to operate the A/C without the charging aid of the ICE, in case the HV is at low bars
