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Difference between revisions of "PiPrius"

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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.
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* 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.
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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==
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==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.
 
 
 
===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.
 
 
 
# Disassemble the dashboard.
 
## Remove the bottom cover of steering column
 
### Releasing the steering wheel adjustment handle and removing the silver screw.
 
### Turn steering wheel 90 degrees to right and left to remove black screws on each side.
 
### Remove the lower cover by carefully pulling down on lower half.
 
## Disconnect the headlamp flasher plug on left side of steering column.
 
### Remove plugs cover by unlocking two side tabs/clips.
 
### Remove 3 unused connector pins ''using a jeweler's screwdriver to disengage and slide them out''.
 
### Optionally to use the headlamp flasher circuit as an EV Mode button:
 
#### <font color=darkblue>Solder ''some length??'' of black wire to a new pin and use it to replace:
 
#### The '''??????''' wire to preserve day time flashing function, will disable night time flashing. ''Preferred''
 
#### The '''purple''' wire to preserve night time flashing function, will disable day time flashing.
 
#### Route new black wire over or under steering column towards passenger side of dash.</font>
 
### Snap the cover back onto the flasher plug and reinsert into switch.
 
### Reassemble steering column, be sure everything is aligned properly.
 
## Remove lower glove box by squeezing the inside sides together to lower box below catches, then unclip the small hydraulic piston from right side. Lower box until the lower joints detach from dash.
 
## Remove passenger side silver air vent cover by pulling out from the bottom first.  Next remove the small interior colored piece just below the vent piece by pulling straight out.
 
## If installing CAN-View Without Navigation:
 
### <font color=darkblue>Remove drivers side air vent cover.
 
### Remove lower center console hump with 12v lighter power socket.
 
### Remove air vent at right side of MFD screen.
 
### Remove lower drivers side dash panel.
 
### Remove lower dash key fob panel.
 
### Remove drivers side dash.
 
### Remove upper drivers side dash panel with power button.
 
### Remove air vent at left side of MFD screen with shift lever.
 
### Remove 10mm bolts, one on each side of MFD screen.
 
### Attach CAN-View video cable to [[MFD]], run cable out directly behind screen.
 
### Tap grey OEM wire for 12v power'', top row 2nd from the left.''
 
### Test, then reassemble center and drivers side of dash.</font>
 
## If installing CAN-View With Navigation:
 
### <font color=darkblue>Route OBDII Cable down drivers side of car.
 
### Connect CAN-View video cables to navigation unit.
 
### Tap grey OEM wire for 12v power.
 
### Test and attach above and to rear of navigation unit.</font>
 
## Solder new pin to ''some length??'' of black wire, ''and optionally the black wire which connects to the headlamp flasher.''
 
## Install pin with black wire(s) to ev-mode button location in HV ECU ''H14#27''.
 
### The HV ECU is the one closest the exterior of the car with grey plugs.
 
### H14 is the lowest of the four connectors.
 
### Pin #27 is located on the most interior (broken into three segments) row, the second from the bottom left corner, in the only open location between two red wires.
 
### Using a jeweler's screwdriver raise the white terminal retainer, fully insert the new pin, and re-compress the retainer.
 
## Route CAN-View OBDII cable to OBDII port located above drivers right knee.
 
## Route all wires (CAN, Video, black EV Mode) under passenger side door trim exiting under hole in carpet below passenger seat.
 
## ''Also route relay cable from below passenger seat under rear passenger side door trim towards rear of car.''
 
## Reassemble passenger side of dash and door trim.
 
# Connect all wires to CAN-View
 
# Configure CAN-View'', should be preconfigured''.
 
## 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>[[Media: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...'''''
 
 
 
===References===
 
 
<references/>
 
<references/>
  
[[Category:PiPrius]]
 
 
[[Category:PHEV]]
 
[[Category:PHEV]]
 
[[Category:Prius]]
 
[[Category:Prius]]
[[Category:Prius PHEV]]
+
[[Category:PiPrius]]

Revision as of 11:19, 15 January 2008

Click show for a short list of the current PHEV conversion and kit options for the Toyota Prius.

For Prius conversion details see the Prius PHEV article and comparisons table.

  1. Ron's Original PriusPlus History and current Contactor Based PriusPlus documentation for DIY projects.
  2. Ryan's PriusBlue is the testbed for DC-DC PFC Based PiPrius kits and documentation for DIY projects.
  3. Toyota OEM Prius PHEV and Prime Could use some work on this page
  4. Enginer China. But the rest of these appear to all be defunct as of 2020?
  5. |~- Hybrids-Plus USA/Colorado/Li -~|~- EnergyCS USA -~|~- Hymotion USA/Canada -~|~- Amberjac UK. -~|~- EDrive USA -~| Peter mentioned Plug-In Conversions |~-

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/>