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Difference between revisions of "PiPrius"

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(OEM HV Battery Modifications: reference)
(Logs: Added MPGe to thumbnails.)
 
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{{TOCright}}
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{{Prius PHEV Options Summary}}{{TOCright}}
  
'''Rich Rudman of [http://www.manzanitamicro.com manzanitamicro], [[User:Rjf|Ryan]], and [[PriusBlue]],''' are working on a [[Prius PHEV]] implementation using an upgraded PFC-30 as a DC-DC converter and charger, and Rich is hoping to develop and offer conversion kits.
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Rich Rudman of [[Manzanita Micro]], [[User:Rjf|Ryan]], and [[PriusBlue]], are working on a [[Prius PHEV]] implementation using a [[MM-PFC|PFC40H]], an upgraded PFC30, as a DC-DC converter and charger.
 +
[[Mk 3 Reg]]s are also used to keep the pack healthy and determine when to stop discharging the new pack.
 +
You can find out more about the [[PiPrius conversion process]] with these instructions.
 +
 
 +
'''Converted Vehicles:'''
 +
# 2006 May - [[PriusBlue]] was/is the original testbed for these kits.
 +
# 2006 Oct - [[WhiteBird]] for Chelan County’s [[Advanced Vehicle Innovations Consortium]].
 +
# 2006 Nov - [[GrayPearl]] for Todd Dore's of the Fox Vally EAA.
 +
# 2007 Sep - The [[Green Car Company]] delivered their first conversion to King County.
 +
 
 +
* [http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=260165466473 ebay #260165466473]
 +
 
 +
Some old pages that need to be cleaned up...
 
* [[Prius PHEV#PFC Based]]
 
* [[Prius PHEV#PFC Based]]
 
** [[Prius PHEV Battery Options#PFC Based]]
 
** [[Prius PHEV Battery Options#PFC Based]]
Line 10: Line 22:
 
* Good Electrical-Boxes at [http://www.canev.com/KitsComp/Components/Electrical-Boxes.html www.canev.com]
 
* Good Electrical-Boxes at [http://www.canev.com/KitsComp/Components/Electrical-Boxes.html www.canev.com]
  
 +
Some EVDL threads
 +
* 2006.08.17 - [http://autos.groups.yahoo.com/group/ev-list-archive/message/72339 Grants,  Re: Plug in Hybrid retro fits for Prius, Escape wanted for NY state fleet.]
 +
* 2006.05.31 - [http://autos.groups.yahoo.com/group/ev-list-archive/message/66842 PiPrius ...]
 +
 +
==Conversion Procedures==
 +
See:
 +
* [[PiPrius conversion process]]
 +
* [[Prius OEM fan control]]
  
 
==Logs==
 
==Logs==
 +
[[Image:capture0040-41.png|thumb|right|[[:Image:Capture004.zip|Cap0040-41]], 11 miles >99.9 mpg<br>3.44 mi/kWh or 116 [[MPGe]]]]
 +
[[Image:capture0060.png|thumb|right|[[:Image:Capture006.zip|Cap0060]], 28 miles 78.5 mpg<br>1.807 mi/kWh or 61 [[MPGe]]]]
 +
[[Image:capture0120.png|thumb|right|[[:Image:Capture012.zip|Cap0120]], 22 miles 58 mpg<br>1.446 mi/kWh or 49 [[MPGe]]]]
 +
 +
Current [[CAN-View]] Relay settings, see [[PiPrius conversion process#CAN-View Configuration]]:
 +
: RL2: Low speed HV mode trigger
 +
: RL3: High speed HV mode trigger
 +
: RL4: OEM/PHEV selection
 +
: RL5: OEM Battery fan control
 +
: RL6: Future use for a OEM->PHEV battery regen mode.
 +
:: RL2 ''(Low)'' and RL2 ''(High)'' speed SOC driven relays are connected in parallel to trigger the PFC to enter NiMH High Voltage setpoint (~242V), otherwise PFC is in NiMH Low Voltage setpoint (~228v).
 +
 
[[CAN-View]] Logs from Initial PHEV Test & Tune runs:
 
[[CAN-View]] Logs from Initial PHEV Test & Tune runs:
[[Image:capture0040-41.png|thumb|right|[[:Image:Capture004.zip|Cap0040-41]], 11 miles >99.9mpg]]
 
[[Image:capture0060.png|thumb|right|[[:Image:Capture006.zip|Cap0060]], 28 miles 78.5mpg]]
 
 
* 2006.05.27 - [[:Image:Capture001.zip]] - 2 short PHEV tests, no relays used, CCL issues, 1 charge.
 
* 2006.05.27 - [[:Image:Capture001.zip]] - 2 short PHEV tests, no relays used, CCL issues, 1 charge.
 
* 2006.05.29 - [[:Image:Capture002.zip]] - 4 PHEV tests, SOC relay trigger, 30.2 miles, 3 charges.
 
* 2006.05.29 - [[:Image:Capture002.zip]] - 4 PHEV tests, SOC relay trigger, 30.2 miles, 3 charges.
Current [[CAN-View]] Relay settings:
 
: RL2: on <69 off >70%SOC & on >70 off <70Acl
 
: RL3: ''unused''
 
: RL4: OEM/PHEV selected & >40Acl & Bat <105degF
 
: RL5: ''unused''
 
: RL6: on <74 off >74%SOC & on >50 off <45mph
 
:: RL2 ''(Low)'' and RL6 ''(High)'' speed SOC driven relays are connected in parallel to trigger the PFC to enter NiMH High Voltage setpoint (239V), otherwise PFC is in NiMH Low Voltage setpoint (227v).
 
 
* 2006.07.15 - [[:Image:Capture003.zip]] - Trip to Manzanita HEV/PHEV mixed-mode
 
* 2006.07.15 - [[:Image:Capture003.zip]] - Trip to Manzanita HEV/PHEV mixed-mode
 
Added LowBatReg, a single MarkIII regulator which communicates with PFC to lower current levels in order to keep ''known'' lowest PbA battery above 10.0v.  Eventually all batteries will have such regulators protecting each from over and under voltage events.  Regs will also enhance the ability to equalize the pack and charge safely without manual monitoring.
 
Added LowBatReg, a single MarkIII regulator which communicates with PFC to lower current levels in order to keep ''known'' lowest PbA battery above 10.0v.  Eventually all batteries will have such regulators protecting each from over and under voltage events.  Regs will also enhance the ability to equalize the pack and charge safely without manual monitoring.
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* 2006.07.20 - [[:Image:Capture008.zip]] - Ryans commute.
 
* 2006.07.20 - [[:Image:Capture008.zip]] - Ryans commute.
 
* 2006.07.23 - [[:Image:Capture009.zip]] - Four consecutive tanks during a road trip.
 
* 2006.07.23 - [[:Image:Capture009.zip]] - Four consecutive tanks during a road trip.
* See also [[PriusBlue Mileage]] & [[Image:MyMileage.zip]] spreadsheets for more trip data and details.
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* 2006.09.16 - [[:Image:Capture010.zip]] - Pair of Mixed mode trips.
 
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* 2006.09.17 - [[:Image:Capture011.zip]] - Short low speed trip.
 +
* 2006.10.02 - [[:Image:Capture012.zip]] - Trip with new relay box, colder weather.
 +
* 2006.11.22 - [[:Image:Capture013.zip]] - Trip from work to apt, need to up NiMH-HighV setpoint to ~240v.
 +
* 2006.11.26 - [[:Image:Capture014.zip]] - Testing with current through OEM HAL sensor, got DTC's @ .95 miles.
 +
* See also [[PriusBlue Mileage]] & [[Image:PriusBlueMileage.zip]] spreadsheets for more trip data and details.
  
 
''Each .zip file contains a main description .txt file similar to the comments which describe it.  There are also multiple CAN-View Capture "raw" .txt files and their resultant .csv files.  Each capture file is described with dash miles-mpg|CAN-View Trip screen miles-mpg|CAN-View Ah Count down from 10Ah, a description of the trip, and the amount of recharge.''
 
''Each .zip file contains a main description .txt file similar to the comments which describe it.  There are also multiple CAN-View Capture "raw" .txt files and their resultant .csv files.  Each capture file is described with dash miles-mpg|CAN-View Trip screen miles-mpg|CAN-View Ah Count down from 10Ah, a description of the trip, and the amount of recharge.''
  
 
==Photos==
 
==Photos==
 +
More photos at:
 +
* [[WhiteBird#Photos]]
 +
* [[GrayPearl#Photos]]
 
<gallery>
 
<gallery>
 
Image:100 1332.JPG|Battery Layout for [[PiPrius]]
 
Image:100 1332.JPG|Battery Layout for [[PiPrius]]
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Image:100 1379.JPG|Other end of CAN-View relays # 2-6
 
Image:100 1379.JPG|Other end of CAN-View relays # 2-6
 
Image:100 1381.JPG|Other end of CAN-View relays # 2-6 (closeup)
 
Image:100 1381.JPG|Other end of CAN-View relays # 2-6 (closeup)
Image:100 1438.JPG|Dry fitting new battery rack
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Image:100 1438.JPG|Dry fitting early battery box
Image:100 1439.JPG|New battery rack and [[MMPFC]]
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Image:100 1439.JPG|Battery box and [[MM-PFC]]
 
Image:100 1440.JPG|Will hold 15 Hawker EP26 or Areo AB26's
 
Image:100 1440.JPG|Will hold 15 Hawker EP26 or Areo AB26's
Image:100 1441.JPG|1 or 3 rails shown which will house battery regs.
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Image:100 1441.JPG|1 of 3 rails shown which will house battery regs.
 
Image:100 1442.JPG|OEM HV tie-in.
 
Image:100 1442.JPG|OEM HV tie-in.
 +
Image:DSC00062.JPG|An early plastic version of the interlock box
 +
Image:DSC00238.JPG|Fitted aluminum cubby area interlock box
 +
Image:DSC00343.JPG|Modular interlock box (far left)
 +
Image:DSC00338.JPG|Tray with regulators for modular battery bank
 +
Image:DSC00341.JPG|Tray with regulators for modular battery bank
 +
Image:DSC00353.JPG|Modular battery box with cover (24 batteries)
 
</gallery>
 
</gallery>
  
==Conversion Procedures==
+
==References==
There are a number of tasks to be completed in order for the entire system to function properly.  Those tasks are covered in the following subsections of the Conversion Procedures.  These instructions are currently under development and may not yet be complete.
+
<references/>
 
 
===CAN-View & EV Mode Button===
 
Installing the [[CAN-View]] and [[Prius EV Mode Button]] both involve disassembling the same areas of the Prius so will be covered here at the same time.
 
  
# Install CAN-View.
 
# Install EV-Mode ''Button''
 
# Configure CAN-View.
 
## RL1 = '''EV-Mode''' Button trigger
 
## RL2 = ''? Voltage dither ?''
 
## RL3 = ''? Regen mode ? ''
 
## RL4 = '''Stock / PHEV''' mode selection
 
## RL5 =
 
## RL6 =
 
 
See also:
 
* [http://www.calcars.org/prius-evbutton-install.pdf prius-evbutton-install.pdf] <ref>[[Media:Prius-evbutton-install.pdf]] from http://www.calcars.org/prius-evbutton-install.pdf</ref>
 
* [http://www.scubadivervideo.com/Files/factoryEV.pdf factoryEV.pdf] <ref>[[Media:FactoryEV.pdf]] from http://www.scubadivervideo.com/Files/factoryEV.pdf</ref>
 
* CAN-View Installation [http://www.hybridinterfaces.ca/installNONAV.html Without] <ref>[[Media:CAN-View installNONAVwt.pdf]] Adapted from http://www.hybridinterfaces.ca/installNONAV.html</ref> or [http://www.hybridinterfaces.ca/installWNAV.html With] <ref>[[Media:CAN-View installWNAVwt.pdf]] Adapted from http://www.hybridinterfaces.ca/installWNAV.html</ref> Navigation.
 
* [https://www.metrotpn.com/documents/PDF%20Files/Prius/Eddie's%20XMRadio%20Install/PriusXMradio3.2.pdf PriusXMradio3.2.pdf] <ref>[[Media:PriusXMradio3.2.pdf]] from https://www.metrotpn.com/documents/PDF%20Files/Prius/Eddie's%20XMRadio%20Install/PriusXMradio3.2.pdf</ref>
 
* [http://www.chrisdragon.com/downloads/Stereo%20Accessory%20Install%20Guide,%2004%20Prius,%20v1.03.pdf Stereo Accessory Install Guide, 04 Prius, v1.03.pdf] <ref>[[Media:Stereo Accessory Install Guide 04 Prius v1.03.pdf]] from http://www.chrisdragon.com/downloads/Stereo%20Accessory%20Install%20Guide,%2004%20Prius,%20v1.03.pdf</ref>
 
 
===OEM HV Battery Modifications===
 
{{Disclaimer}}
 
A number of wires are added within the OEM HV Battery box, including two HV cables which will exit the box and a short HV jumper cable through the HAL sensor.  In addition one or more low voltage wires and taps may be added.
 
 
# Remove trunk carpet, all storage compartments, and spare tire.
 
# '''! ! Be Sure To Remove Orange HV Service Plug ! !'''
 
# Install HV taps to OEM NiMH battery Pack
 
## Remove rear seat bottom, pull up front edge, unhook rear edge
 
## Remove rear battery deck upholstery ''2x tie down clips ?10mm?, 2x tabs''
 
## Remove drivers side rear seat back ''2x 14mm''
 
## Remove drivers side rear seat pillow upholstery ''12mm, pull up''
 
## Remove drivers side trunk panel upholstery ''10mm, 10mm screw, tabs''
 
## Remove drivers side OEM Battery brace ''7x 12mm''
 
## Remove OEM Battery ECU Cover ''2x 10mm, 2x 10mm nuts''
 
### ''Optional steps'' <font color=red>'''Caution:''' This will expose you to the OEM HV Modules
 
### Remove OEM Battery Input Air Duct ''2x tape, 1 sensor''
 
### Remove Passenger side OEM Battery brace ''7x 12mm''
 
### Remove '''OEM Battery Lid''' ''4x 12mm, 4x 10mm, 4x 10mm nuts, 1 tab at end''</font>
 
## Add New HV Cables, Notch Here, Trim There, etc, etc
 
## Reassemble in reverse order
 
# '' Replace Orange HV Service Plug ''
 
 
See Also:
 
*[http://www.airlabcorp.com/Prius/priusdisman.pdf PriusDisMan.pdf] <ref>[[:Image:Priusdisman.pdf]] from http://www.airlabcorp.com/Prius/priusdisman.pdf</ref>
 
 
===Mount PFC Charger===
 
Install PFC Charger in the drivers side rear wheel well.
 
 
# Locate and drill mount points from pattern
 
# Install ventilation housing and fans
 
# Mount PFC Charger
 
 
===Install Battery Box===
 
{{Disclaimer}}
 
 
Install the Battery Box.
 
# Locate, drill, and ''press nut'' body/frame mountpoints
 
# Attach ''Electronics Box'' to bottom of lower battery box frame
 
# Install and fasten lower battery box frame
 
# Populate box with batteries
 
# Install battery regulators and interconnects
 
# Install and fasten upper battery box frame
 
 
===Connect Relay Box===
 
# Connect everything...
 
 
===Drive and Enjoy===
 
'''Charge, Drive, and ''Repeat...'''''
 
 
[[Category:PiPrius]]
 
 
[[Category:PHEV]]
 
[[Category:PHEV]]
 
[[Category:Prius]]
 
[[Category:Prius]]
[[Category:Prius PHEV]]
+
[[Category:PiPrius]]

Latest revision as of 11:19, 15 January 2008

Rich Rudman of Manzanita Micro, Ryan, and PriusBlue, are working on a Prius PHEV implementation using a PFC40H, an upgraded PFC30, as a DC-DC converter and charger. Mk 3 Regs are also used to keep the pack healthy and determine when to stop discharging the new pack. You can find out more about the PiPrius conversion process with these instructions.

Converted Vehicles:

  1. 2006 May - PriusBlue was/is the original testbed for these kits.
  2. 2006 Oct - WhiteBird for Chelan County’s Advanced Vehicle Innovations Consortium.
  3. 2006 Nov - GrayPearl for Todd Dore's of the Fox Vally EAA.
  4. 2007 Sep - The Green Car Company delivered their first conversion to King County.

Some old pages that need to be cleaned up...

Misc development related stuff:

Some EVDL threads

Conversion Procedures

See:

Logs

Cap0040-41, 11 miles >99.9 mpg
3.44 mi/kWh or 116 MPGe
Cap0060, 28 miles 78.5 mpg
1.807 mi/kWh or 61 MPGe
Cap0120, 22 miles 58 mpg
1.446 mi/kWh or 49 MPGe

Current CAN-View Relay settings, see PiPrius conversion process#CAN-View Configuration:

RL2: Low speed HV mode trigger
RL3: High speed HV mode trigger
RL4: OEM/PHEV selection
RL5: OEM Battery fan control
RL6: Future use for a OEM->PHEV battery regen mode.
RL2 (Low) and RL2 (High) speed SOC driven relays are connected in parallel to trigger the PFC to enter NiMH High Voltage setpoint (~242V), otherwise PFC is in NiMH Low Voltage setpoint (~228v).

CAN-View Logs from Initial PHEV Test & Tune runs:

Added LowBatReg, a single MarkIII regulator which communicates with PFC to lower current levels in order to keep known lowest PbA battery above 10.0v. Eventually all batteries will have such regulators protecting each from over and under voltage events. Regs will also enhance the ability to equalize the pack and charge safely without manual monitoring.

Restored OEM cooling system to original state, finished testing degraded OEM cooling.

Each .zip file contains a main description .txt file similar to the comments which describe it. There are also multiple CAN-View Capture "raw" .txt files and their resultant .csv files. Each capture file is described with dash miles-mpg|CAN-View Trip screen miles-mpg|CAN-View Ah Count down from 10Ah, a description of the trip, and the amount of recharge.

Photos

More photos at:

References

<references/>