|Click show for a short list of the current PHEV conversion and kit options for the Toyota Prius.|
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.
- 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.
Some old pages that need to be cleaned up...
- Prius PHEV#PFC Based
Misc development related stuff:
- Good Electrical-Boxes at www.canev.com
Some EVDL threads
- 2006.08.17 - Grants, Re: Plug in Hybrid retro fits for Prius, Escape wanted for NY state fleet.
- 2006.05.31 - PiPrius ...
 Conversion Procedures
- 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:
- 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.
- 2006.07.15 - 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.
- 2006.07.16 - Image:Capture004.zip - 3 short mostly EV-Only trips & a P3000 DTC.
Restored OEM cooling system to original state, finished testing degraded OEM cooling.
- 2006.07.17 - Image:Capture005.zip - Ryans commute, and repeat of Cap004.
- 2006.07.18 - Image:Capture006.zip - Ryans commute, much improved performance on return trip.
- 2006.07.19 - Image:Capture007.zip - Ryans commute.
- 2006.07.20 - Image:Capture008.zip - Ryans commute.
- 2006.07.23 - Image:Capture009.zip - Four consecutive tanks during a road trip.
- 2006.09.16 - Image:Capture010.zip - Pair of Mixed mode trips.
- 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.
More photos at:
CAN-View v2 with new relay board wired,
Battery box and MM-PFC