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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

[edit] Conversion Procedures


[edit] Logs

Cap0040-41, 11 miles >99.9 mpg3.44 mi/kWh or 116 MPGe
Cap0040-41, 11 miles >99.9 mpg
3.44 mi/kWh or 116 MPGe
Cap0060, 28 miles 78.5 mpg1.807 mi/kWh or 61 MPGe
Cap0060, 28 miles 78.5 mpg
1.807 mi/kWh or 61 MPGe
Cap0120, 22 miles 58 mpg1.446 mi/kWh or 49 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.

[edit] Photos

More photos at:

[edit] References

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