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

Difference between pages "PiPrius" and "PiPrius conversion process"

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(→‎CAN-View & EV Mode Button: CAN-View settings)
 
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{{TOCright}}
  
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'''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.  Find out more about the [[PiPrius conversion process]].
+
These are the steps involved to convert a [[Toyota Prius]] into a [[PiPrius]].  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.
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* [[Prius PHEV#PFC Based]]
 
−
** [[Prius PHEV Battery Options#PFC Based]]
 
−
** [[State Of Charge Manipulation#PFC Based]]
 
−
** [[Prius PHEV Schematics#PFC Based]]
 
  
−
Misc development related stuff:
+
==References==
−
* Good Electrical-Boxes at [http://www.canev.com/KitsComp/Components/Electrical-Boxes.html www.canev.com]
+
You should be familiar with these reference materials and standard operating procedures around high voltages.
 +
<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.
  
−
==Logs==
+
# Disassemble the dashboard.
−
[[CAN-View]] Logs from Initial PHEV Test & Tune runs:
+
## Remove the bottom cover of steering column
−
[[Image:capture0040-41.png|thumb|right|[[:Image:Capture004.zip|Cap0040-41]], 11 miles >99.9mpg]]
+
### Releasing the steering wheel adjustment handle and removing the silver screw.
−
[[Image:capture0060.png|thumb|right|[[:Image:Capture006.zip|Cap0060]], 28 miles 78.5mpg]]
+
### Turn steering wheel 90 degrees to right and left to remove black screws on each side.
−
* 2006.05.27 - [[:Image:Capture001.zip]] - 2 short PHEV tests, no relays used, CCL issues, 1 charge.
+
### Remove the lower cover by carefully pulling down on lower half.
−
* 2006.05.29 - [[:Image:Capture002.zip]] - 4 PHEV tests, SOC relay trigger, 30.2 miles, 3 charges.
+
## Disconnect the headlamp flasher plug on left side of steering column.
−
Current [[CAN-View]] Relay settings:
+
### Remove plugs cover by unlocking two side tabs/clips.
−
: RL2: on <69 off >70%SOC & on >70 off <70Acl
+
### Remove 3 unused connector pins ''using a jeweler's screwdriver to disengage and slide them out''.
−
: RL3: ''unused''
+
### Optionally to use the headlamp flasher circuit as an EV Mode button:
−
: RL4: OEM/PHEV selected & >40Acl & Bat <105degF
+
#### <font color=darkblue>Solder ''some length??'' of black wire to a new pin and use it to replace:
−
: RL5: ''unused''
+
#### The '''??????''' wire to preserve day time flashing function, will disable night time flashing. ''Preferred''
−
: RL6: on <74 off >74%SOC & on >50 off <45mph
+
#### The '''purple''' wire to preserve night time flashing function, will disable day time flashing.
−
:: 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).
+
#### Route new black wire over or under steering column towards passenger side of dash.</font>
−
* 2006.07.15 - [[:Image:Capture003.zip]] - Trip to Manzanita HEV/PHEV mixed-mode
+
### Snap the cover back onto the flasher plug and reinsert into switch.
−
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.
+
### Reassemble steering column, be sure everything is aligned properly.
−
* 2006.07.16 - [[:Image:Capture004.zip]] - 3 short mostly EV-Only trips & a P3000 DTC.
+
## 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.
−
Restored OEM cooling system to original state, finished testing degraded OEM cooling.
+
## 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.
−
* 2006.07.17 - [[:Image:Capture005.zip]] - Ryans commute, and repeat of Cap004.
+
## If installing CAN-View Without Navigation:
−
* 2006.07.18 - [[:Image:Capture006.zip]] - Ryans commute, much improved performance on return trip.
+
### <font color=darkblue>Remove drivers side air vent cover.
−
* 2006.07.19 - [[:Image:Capture007.zip]] - Ryans commute.
+
### Remove lower center console hump with 12v lighter power socket.
−
* 2006.07.20 - [[:Image:Capture008.zip]] - Ryans commute.
+
### Remove air vent at right side of MFD screen.
−
* 2006.07.23 - [[:Image:Capture009.zip]] - Four consecutive tanks during a road trip.
+
### Remove lower drivers side dash panel.
−
* See also [[PriusBlue Mileage]] & [[Image:MyMileage.zip]] spreadsheets for more trip data and details.
+
### 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
 +
## RL4 on if bat.temp. < '''+111''' DegF
 +
## RL4 on if CCL is > '''40''' ACL
 +
## Battery Capacity '''10.0Ah'''
 +
## RL2 = < 69 > 70% SOC and > 70 < 70 ACL, 0s, NO
 +
## RL3 = < 74 > 74% SOC and > 50 < 45 MPH, 0s, NO
 +
## RL5 = ''Regen ?''
 +
## RL6 = ''HeartBeat ?''
  
 +
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>
  
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''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.''
+
==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.
  
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==Photos==
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# Remove trunk carpet, all storage compartments, and spare tire.
−
<gallery>
+
# '''! ! Be Sure To Remove Orange HV Service Plug ! !'''
−
Image:100 1332.JPG|Battery Layout for [[PiPrius]]
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# Install HV taps to OEM NiMH battery Pack
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Image:100 1335.JPG|Reverting previous battery tap & HV modifications
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## Remove rear seat bottom, pull up front edge, unhook rear edge
−
Image:100 1378.JPG|PFC-30(40A) mounted in drivers corner.
+
## Remove rear battery deck upholstery ''2x tie down clips ?10mm?, 2x tabs''
−
Image:100 1377.JPG|[[CAN-View]] v2 with new relay board wired,
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## Remove drivers side rear seat back ''2x 14mm''
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Image:100 1379.JPG|Other end of CAN-View relays # 2-6
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## Remove drivers side rear seat pillow upholstery ''12mm, pull up''
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Image:100 1381.JPG|Other end of CAN-View relays # 2-6 (closeup)
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## Remove drivers side trunk panel upholstery ''10mm, 10mm screw, tabs''
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Image:100 1438.JPG|Dry fitting new battery rack
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## Remove drivers side OEM Battery brace ''7x 12mm''
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Image:100 1439.JPG|New battery rack and [[MMPFC]]
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## Remove OEM Battery ECU Cover ''2x 10mm, 2x 10mm nuts''
−
Image:100 1440.JPG|Will hold 15 Hawker EP26 or Areo AB26's
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### ''Optional steps'' <font color=red>'''Caution:''' This will expose you to the OEM HV Modules
−
Image:100 1441.JPG|1 or 3 rails shown which will house battery regs.
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### Remove OEM Battery Input Air Duct ''2x tape, 1 sensor''
−
Image:100 1442.JPG|OEM HV tie-in.
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### Remove Passenger side OEM Battery brace ''7x 12mm''
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</gallery>
+
### 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 ''
  
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==Conversion Procedures==
+
See Also:
−
See: [[PiPrius conversion process]]
+
*[http://www.airlabcorp.com/Prius/priusdisman.pdf PriusDisMan.pdf] <ref>[[Media:Priusdisman.pdf]] from http://www.airlabcorp.com/Prius/priusdisman.pdf</ref>
  
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==References==
+
==Mount PFC Charger==
−
<references/>
+
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:PiPrius]]

Revision as of 09:29, 23 September 2006

These are the steps involved to convert a Toyota Prius into a PiPrius. 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

You should be familiar with these reference materials and standard operating procedures around high voltages. <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.

  1. Disassemble the dashboard.
    1. Remove the bottom cover of steering column
      1. Releasing the steering wheel adjustment handle and removing the silver screw.
      2. Turn steering wheel 90 degrees to right and left to remove black screws on each side.
      3. Remove the lower cover by carefully pulling down on lower half.
    2. Disconnect the headlamp flasher plug on left side of steering column.
      1. Remove plugs cover by unlocking two side tabs/clips.
      2. Remove 3 unused connector pins using a jeweler's screwdriver to disengage and slide them out.
      3. Optionally to use the headlamp flasher circuit as an EV Mode button:
        1. Solder some length?? of black wire to a new pin and use it to replace:
        2. The ?????? wire to preserve day time flashing function, will disable night time flashing. Preferred
        3. The purple wire to preserve night time flashing function, will disable day time flashing.
        4. Route new black wire over or under steering column towards passenger side of dash.
      4. Snap the cover back onto the flasher plug and reinsert into switch.
      5. Reassemble steering column, be sure everything is aligned properly.
    3. 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.
    4. 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.
    5. If installing CAN-View Without Navigation:
      1. Remove drivers side air vent cover.
      2. Remove lower center console hump with 12v lighter power socket.
      3. Remove air vent at right side of MFD screen.
      4. Remove lower drivers side dash panel.
      5. Remove lower dash key fob panel.
      6. Remove drivers side dash.
      7. Remove upper drivers side dash panel with power button.
      8. Remove air vent at left side of MFD screen with shift lever.
      9. Remove 10mm bolts, one on each side of MFD screen.
      10. Attach CAN-View video cable to MFD, run cable out directly behind screen.
      11. Tap grey OEM wire for 12v power, top row 2nd from the left.
      12. Test, then reassemble center and drivers side of dash.
    6. If installing CAN-View With Navigation:
      1. Route OBDII Cable down drivers side of car.
      2. Connect CAN-View video cables to navigation unit.
      3. Tap grey OEM wire for 12v power.
      4. Test and attach above and to rear of navigation unit.
    7. Solder new pin to some length?? of black wire, and optionally the black wire which connects to the headlamp flasher.
    8. Install pin with black wire(s) to ev-mode button location in HV ECU H14#27.
      1. The HV ECU is the one closest the exterior of the car with grey plugs.
      2. H14 is the lowest of the four connectors.
      3. 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.
      4. Using a jeweler's screwdriver raise the white terminal retainer, fully insert the new pin, and re-compress the retainer.
    9. Route CAN-View OBDII cable to OBDII port located above drivers right knee.
    10. Route all wires (CAN, Video, black EV Mode) under passenger side door trim exiting under hole in carpet below passenger seat.
    11. Also route relay cable from below passenger seat under rear passenger side door trim towards rear of car.
    12. Reassemble passenger side of dash and door trim.
  2. Connect all wires to CAN-View
  3. Configure CAN-View, should be preconfigured.
    1. RL1 = EV-Mode Button trigger
    2. RL4 on if bat.temp. < +111 DegF
    3. RL4 on if CCL is > 40 ACL
    4. Battery Capacity 10.0Ah
    5. RL2 = < 69 > 70% SOC and > 70 < 70 ACL, 0s, NO
    6. RL3 = < 74 > 74% SOC and > 50 < 45 MPH, 0s, NO
    7. RL5 = Regen ?
    8. RL6 = HeartBeat ?

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...

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