General Disclaimer:   (HV) (DC) injury or death hazard,   use at your own risk,   may void warranty.

PiPrius

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Revision as of 04:18, 22 September 2006 by Rjf (talk | contribs) (→‎OEM HV Battery Modifications: Media:)
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Rich Rudman of manzanitamicro, 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.

Misc development related stuff:


Logs

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

Cap0040-41, 11 miles >99.9mpg
Cap0060, 28 miles 78.5mpg

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).

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

Conversion Procedures

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.

  1. Install CAN-View.
  2. Install EV-Mode Button
  3. Configure CAN-View.
    1. RL1 = EV-Mode Button trigger
    2. RL2 = ? Voltage dither ?
    3. RL3 = ? Regen mode ?
    4. RL4 = Stock / PHEV mode selection
    5. RL5 =
    6. RL6 =

See also:

OEM HV Battery Modifications

General Disclaimer:   (HV) (DC) injury or death hazard,   use at your own risk,   may void warranty.

HV (High Voltage) DC (Direct Current) Warning: Traction Battery Packs, Motors, Chargers, and other HV sources could cause serious injury or death if proper precautions are not taken while working on or around such High Voltage Direct Current sources.

Use this information at your own risk: There is no warranty expressed nor implied and we are not liable for any of your past, present, nor future actions. Even should you perform these modifications to the letter you could still damage any number of components in your vehicle causing it to no longer function. Even if it appears to function properly your actions may cause it to self destruct with collateral damage to surrounding properties other than your vehicle. By utilizing these ideas and instructions in an attempting to enhance national security, reduce gas consumption, vehicle "emissions", your carbon footprint, or smog, you do so at your own risk & peril.

Warranty: In performing some of these modifications you may void your warranty with the vehicles manufacturer.

See also our My wiki:General 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.

  1. Remove trunk carpet, all storage compartments, and spare tire.
  2. ! ! Be Sure To Remove Orange HV Service Plug ! !
  3. Install HV taps to OEM NiMH battery Pack
    1. Remove rear seat bottom, pull up front edge, unhook rear edge
    2. Remove rear battery deck upholstery 2x tie down clips ?10mm?, 2x tabs
    3. Remove drivers side rear seat back 2x 14mm
    4. Remove drivers side rear seat pillow upholstery 12mm, pull up
    5. Remove drivers side trunk panel upholstery 10mm, 10mm screw, tabs
    6. Remove drivers side OEM Battery brace 7x 12mm
    7. Remove OEM Battery ECU Cover 2x 10mm, 2x 10mm nuts
      1. Optional steps Caution: This will expose you to the OEM HV Modules
      2. Remove OEM Battery Input Air Duct 2x tape, 1 sensor
      3. Remove Passenger side OEM Battery brace 7x 12mm
      4. Remove OEM Battery Lid 4x 12mm, 4x 10mm, 4x 10mm nuts, 1 tab at end
    8. Add New HV Cables, Notch Here, Trim There, etc, etc
    9. Reassemble in reverse order
  4. Replace Orange HV Service Plug

See Also:

Mount PFC Charger

Install PFC Charger in the drivers side rear wheel well.

  1. Locate and drill mount points from pattern
  2. Install ventilation housing and fans
  3. Mount PFC Charger

Install Battery Box

General Disclaimer:   (HV) (DC) injury or death hazard,   use at your own risk,   may void warranty.

HV (High Voltage) DC (Direct Current) Warning: Traction Battery Packs, Motors, Chargers, and other HV sources could cause serious injury or death if proper precautions are not taken while working on or around such High Voltage Direct Current sources.

Use this information at your own risk: There is no warranty expressed nor implied and we are not liable for any of your past, present, nor future actions. Even should you perform these modifications to the letter you could still damage any number of components in your vehicle causing it to no longer function. Even if it appears to function properly your actions may cause it to self destruct with collateral damage to surrounding properties other than your vehicle. By utilizing these ideas and instructions in an attempting to enhance national security, reduce gas consumption, vehicle "emissions", your carbon footprint, or smog, you do so at your own risk & peril.

Warranty: In performing some of these modifications you may void your warranty with the vehicles manufacturer.

See also our My wiki:General disclaimer

Install the Battery Box.

  1. Locate, drill, and press nut body/frame mountpoints
  2. Attach Electronics Box to bottom of lower battery box frame
  3. Install and fasten lower battery box frame
  4. Populate box with batteries
  5. Install battery regulators and interconnects
  6. Install and fasten upper battery box frame

Connect Relay Box

  1. Connect everything...

Drive and Enjoy

Charge, Drive, and Repeat...

References

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