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Difference between revisions of "PriusPlus-Electronic"

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Another Paragraph and such, you can get help at our [[Help:Contents#How do I use the Wiki Website]] page <ref>http://en.wikipedia.org/wiki/Help:Contents more help using the wiki.</ref>  Feel free to simply remove or if you like move all of this example text to the pages discussion article.
 
Another Paragraph and such, you can get help at our [[Help:Contents#How do I use the Wiki Website]] page <ref>http://en.wikipedia.org/wiki/Help:Contents more help using the wiki.</ref>  Feel free to simply remove or if you like move all of this example text to the pages discussion article.
 
==TODO==
 
 
* Electrical
 
HV wiring, Battery charger, Heater/Charger relays
 
 
* CAN-View instructions for the V4 need to be added. I can update this by Dec.10 -Jim P.
 
  
 
==Control Board==
 
==Control Board==

Revision as of 19:30, 12 March 2007

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 |~-

--={ Project Overview }={ 2007 Maker Faire }={ Theory }={ Instructions }={ Parts List }={ RawData }={ Latest News }=--
--={ Doc Process }={ Mechanical }={ Electrical }={ Electronic }={ Interest }={ Talk:PriusPlus Main Discussion }=--

--={ Historic }={ Battery }={ Schematics }={ PseudoCode }={ Photos }=--

Team Photo from the PriusPlus conversion of Sven's Prius from Nov 2006.

This is the home of the PRIUS+ PHEV DIY (Do-it-Yourself) documentation. These pages are currently anonymously editable, which may change in the future. Please feel free to use the Discussion page for general discussion and commentary on the main article. If you would like to add to an existing section use the "edit" link near that topic's heading. Don't forget to use the Summary field to describe your changes. While editing use the "Show Preview" button to make sure your changes look like you expect them to, before you click "Save Page".



Intro Paragraph here maybe with a link to the main PriusPlus article, links to external sites can appear as formatted CalCars, just plain URLs like http://www.calcars.com, or fancy references such as that in the next paragraph.

Another Paragraph and such, you can get help at our Help:Contents#How do I use the Wiki Website page <ref>http://en.wikipedia.org/wiki/Help:Contents more help using the wiki.</ref> Feel free to simply remove or if you like move all of this example text to the pages discussion article.

Control Board

Control Board, ExpressSCH Schematic

Approx. time requirement:

Todo: link to theory

Tools Needed

  • Soldering Iron
  • Solder

Parts List

The public DigiKey parts list for the control board can be found here


Parts list for Control Board Schematic

Parts List for CalCars' PRIUS+ Control Board V4.2 and LED Board V1.1

Ronald Gremban, 1/21/2007








Quantity Value DigiKey Number Board Designators Min Qty Est Cost Est Cost

Misc



Total
1 4.7nF Capacitor 495-2555-ND C5
$0.13 $0.13
13 0.1uF Capacitor 495-1147-ND C6,C7,C14-18,C22-27
$0.17 $2.21
6 0.47uF Capacitor 495-1160-ND C8-13
$0.35 $2.10
1 22uF,20V Cap P13461-ND C4
$0.11 $0.11
6 100uF,20V Cap P13476-ND C1-3,C19-21
$0.14 $0.84
2 10PST DIP switch CKN3028-ND DIPSW1, DIPSW2
$2.21 $4.42
2 15A blade fuse F992-ND F1,F2 5 $0.46 $2.30
2 rt. angle socket F064-ND (for blade fuses) F1,F2
$1.83 $3.66
1 Omron SPDT Relay Z785-ND (or DPDT Z790-ND, $7.58) RL1
$6.45 $6.45
1 Relay Socket Z792-ND socket RL1
$1.80 $1.80
1 Relay holddown clip Z796-ND (for Z792-ND socket) RL1
$0.28 $0.28








Connectors




4 2-pin 0.1" Molex WM4200-ND J6M,J7M,J10M,J20M
$0.34 $1.36
1 3-pin 0.1" Molex WM4201-ND J2M
$0.43 $0.43
9 2-pin 0.156" Molex WM4620-ND J11M–19M
$0.31 $2.79
1 3-pin 0.156" Molex WM4621-ND J3M
$0.41 $0.41
1 4-pin 0.156" Molex WM4622-ND J4M
$0.51 $0.51
1 5-pin 0.156" Molex WM4623-ND J8M
$0.41 $0.41
1 6-pin 0.156" Molex WM4624-ND J5M
$0.71 $0.71
1 Jumper: 2-pin male WM4000-ND JP1
$0.28 $0.28
1 D15 female 6215FE-nd J1F
$2.41 $2.41
1 16-pin male ribbon CHS16G-ND J9M
$1.46 $1.46








Semiconductors




2 1N5404 1N5404-TPCT-ND D1,D2 10 $0.15 $1.50
10 1N4004 1N4004-TPMSCT-ND D3-9,D11-13 10 $0.04 $0.43
1 MJE2955 497-2621-5-ND, TO-220 Q1
$1.04 $1.04
2 MJE3055 497-2573-5-ND, TO-220 Q16-17
$0.99 $1.98
3 2N3904 2N3904FS-ND, TO-92 Q2-3,Q15
$0.11 $0.33
11 TIP127 TIP127FS-ND, TO-220 Q4-14
$0.63 $6.93
1 STSA1805 497-3531-ND, TO-92 Q18
$1.13 $1.13
1 3mm grn LED 511-1189-ND D10
$0.61 $0.61








ICs




1 LM7812 LM340T-12-ND U9
$1.66 $1.66
2 CD4072 (14-pin DIP) 296-2063-5-ND U1,U2
$0.55 $1.10
2 CD4082 (14-pin DIP) 296-2067-5-ND U3,U4
$0.55 $1.10
2 CD4049 (16-pin DIP) CD4049UBCN-ND U5,U8
$0.48 $0.96
1 CD4081 (14-pin DIP) 296-2066-5-ND U6
$0.55 $0.55
1 LM339 LM339ANFS-ND U7
$0.55 $0.55
6 14-pin DIP socket AE10012-ND or ED90049-ND U1-4,U6, U7
$0.69 $4.14
2 16-pin DIP socket AE7216-ND or ED90050-ND U5,U8
$0.72 $1.44








Resistors




1 330 P330BACT-ND R9 10 $0.07 $0.67
5 1K P1.0KBACT-ND R31,R34,R36,R38,R40 10 $0.07 $0.67
2 1.5K P1.5KBACT-ND R4,R5 10 $0.07 $0.67
1 2.2K P2.2KBACT-ND R3,R12 10 $0.07 $0.67
2 5.1K P5.1KBACT-ND R16,R22 10 $0.07 $0.67
2 6.2K P6.2KBACT-ND R17,R18 10 $0.07 $0.67
1 6.8K P6.8KBACT-ND R23 10 $0.07 $0.67
10 10K P10KBACT-ND R6,R10,R14,R28-30,R32-33,R35,R37 10 $0.07 $0.67
1 20K P20KBACT-ND R13 10 $0.07 $0.67
1 33K P33KBACT-ND R8 10 $0.07 $0.67
1 100K P100KBACT-ND R7 10 $0.07 $0.67
1 200K P200KBACT-ND R15 10 $0.07 $0.67
7 1M P1.0MBACT-ND R19-21,R24-27 10 $0.07 $0.67
1 10M 10MEBK-nd R11 5 $0.05 $0.26
1 2K pot 490-2746-ND R1
$1.05 $1.05
1 5K pot 490-2757-ND R2
$1.05 $1.05
2 100 770-63-R100P-ND (3 iso) RN1,RN2
$0.21 $0.42
2 10K 770-81-R10KP-ND (7 bus) RN3,RN12
$0.34 $0.68
2 100K 770-101-R100KP-ND (9 bus) RN4,RN5
$0.42 $0.84
4 1K 770-63-R1KP-ND (3 iso) RN6,RN7,RN10,RN11
$0.28 $1.12
1 100K 770-61-R100KP-ND (5 bus) RN9
$0.28 $0.28







147




$74.87


Assembly Steps

Solder the components to the printed board according to the schematics above. Make sure to install R3, D1 & D2 1/4 inches off the board and to solder the DIP sockets without the IC's installed. If new at soldering, make sure to use a heat sink for soldering transistors.

Installation

  1. See PriusPlus-Mechanical for instructions for physically mounting the control board.
  • Add a drawing of the control board schematic labeling connectors
  • Show what connects where

Setup

Need instructions on how to adjust the pots for the correct temperature.

Troubleshooting

The LED board will provide useful information for debugging the control board.

LED Board

Approx. time requirement:

Tools Needed

  • Soldering Iron
  • Solder

Parts Needed

The public DigiKey parts list for the LED board can be found here

Parts list for LED Board Schematic

Parts List for CalCars' PRIUS+ LED Board V1.1

Ronald Gremban, 1/21/2007








Quantity Value DigiKey Number Board Designators
Est Cost Est Cost

Connectors



Total
1 16-pin male ribbon CHS16G-ND (CHS116G was in error) LJ1M
$1.46 $1.46








Semiconductors




2 3mm red LED 511-1188-ND LD1,LD11
$0.61 $1.22
2 3mm or-red LED 160-1667-ND DL7,LD12
$0.13 $0.26
1 3mm orange LED 511-1209-ND LD9
$0.80 $0.80
2 3mm yel LED 511-1213-ND LD3,LD10
$0.61 $1.22
2 3mm grn LED 511-1189-ND LD6,LD13
$0.61 $1.22
2 3mm blu-grn LED 365-1174-ND LD2,LD4
$1.23 $2.46
1 3mm blue LED 160-1600-ND LD8
$0.60 $0.60
2 3mm white LED 160-1734-5-ND LD5,LD14
$1.29 $2.58








Resistors




1 510, 1/2W P510BBCT-ND LR1 10 $0.10 $0.95
3 1K P1.0KBACT-ND LR6,LR11,LR13 10 $0.07 $0.67
1 1.8K P1.8KBACT-ND LR8 10 $0.07 $0.67
2 2.7K P2.7KBACT-ND LR3,LR10 10 $0.07 $0.67
3 3K P3.0KBACT-ND LR7,LR9,LR12 10 $0.07 $0.67
2 7.5K P7.5KBACT-ND LR5,LR14 10 $0.07 $0.67
2 20K P20KBACT-ND LR2,LR4 10 $0.07 $0.67







29




$16.79





















CAN-View & EV Mode button

Overview

You will need to purchase CAN-View from hybridinterfaces.ca. There are currently 2 versions of CAN-View available. Version 3 requires an '04 or '05 Prius and makes use of the built in display (or MFD) while Version 4 works with an 04-07 Prius but requires an external touchscreen (since the built in touchscreens were changed in the '06 model and are no longer compatible.) Version 3 has the PHEV relays built onto the main board, while version 2 has an extra optional PHEV relay board. This PHEV relay board is required for this conversion.

Installation

Approx. time requirement: 1-2 hours

CAN-View is installed differently depending on whether or not your car is equipped with in-dash navigation. Detailed instructions with photos are available with NAV or without NAV. It is best to install and route the wires for the Prius EV Mode Button at the same time since they both require disassembling the dash.

ToDo this block of text was lifted from PiPrius_conversion_process#CAN-View_.26_EV_Mode_Button and needs to be reviewed and modified to reflect our wiring. it is NOT done.

  1. Disassemble the dashboard. <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> <ref>Media:PriusXMradio3.2.pdf from https://www.metrotpn.com/documents/PDF%20Files/Prius/Eddie's%20XMRadio%20Install/PriusXMradio3.2.pdf</ref>
    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 Red(#11-B10) wire to preserve day time flashing function, will disable night time flashing.
        3. The Violet(#17-B4) wire to preserve night time flashing function, will disable day time flashing.
        4. Route new black wire along existing bundle then towards center console to later meet up with OBDII cable.
      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 piston from right side. Lower box until the lower joints detach from dash, remove pneumatic cylinder noting it's orientation.
    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: <ref>Media:CAN-View installNONAVwt.pdf Adapted from http://www.hybridinterfaces.ca/installNONAV.html</ref>
      1. Remove drivers side air vent cover, press down and pull out on top.
      2. Remove lower center console hump with 12v lighter power socket, remove barb from passenger side, pull out.
      3. Remove air vent at right side of MFD screen, open upper glove box to pull out vent.
      4. Remove lower drivers side interior colored dash panel, one black screw above hood release, one exposed behind drivers side vent.
      5. Remove black lower dash key fob panel, leave hanging with wires connected.
      6. Remove upper drivers side dash panel with power button, leave wires attached.
      7. Remove air vent at left side of MFD screen, the shift lever with remain in place, detach and slide park button forward through silver panel to expose and detach cable, then remove the panel and reattach the park button to it's cable to prevent errors during later tests.
      8. Remove 10mm bolts, one on each side of MFD screen, pull screen out sharply and rotate towards drivers side.
      9. Tap grey OEM wire for 12v power, top row 2nd from the left.
      10. Attach CAN-View video cable to MFD and power spade to tapped grey wire, run cable out directly behind screen.
      11. Connect CAN-View OBDII cable to OBDII port and route cable behind center console towards glove box along with headlamp flasher ev-mode button wire if installed.
      12. Test CAN-View, then reassemble center and drivers side of dash.
      13. CAN-View will be mounted under passenger seat, above JBL amplifier if present.
    6. If installing CAN-View With Navigation: <ref>Media:CAN-View installWNAVwt.pdf Adapted from http://www.hybridinterfaces.ca/installWNAV.html</ref>
      1. Route OBDII Cable around foot well and down drivers side door sill to underneath drivers seat. Route headlamp flasher ev-mode button wire if installed behind center console and glove box.
      2. Tap gray OEM wire from navigation unit for 12v power.
      3. Connect CAN-View video cables to navigation unit.
      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. <ref>Media:Prius-evbutton-install.pdf from http://www.calcars.org/prius-evbutton-install.pdf</ref> <ref>Media:FactoryEV.pdf from http://www.scubadivervideo.com/Files/factoryEV.pdf</ref>
      1. The HV ECU is the one closest the exterior of the car with gray 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, re-compress the retainer, and plug terminal back into HV ECU.
    9. Route black EV Mode wire, and OBDII & Video if non-NAV, along passenger side door trim exiting under carpet before pillar to the hole in carpet below passenger seat and to relay cable.
    10. Route relay cable from CAN-View under rear passenger side door trim towards rear of car.
    11. Reassemble passenger side of dash and door trim.
  2. Connect all wires to CAN-View
    1. ToDo

Configuration

  1. Configure CAN-ViewToDo, these are PiPrius not PriusPlus settings .
    1. RL1 = EV-Mode Button trigger ToDo
    2. RL4 on if bat.temp. < +111 DegF ToDo
    3. RL4 on if CCL is > 40 ACL ToDo
    4. Battery Capacity 10.0Ah ToDo
    5. RL2 = < 0 > 0% SOC and > 0 < 0 ACL, 0s, NO ToDo
    6. RL3 = < 0 > 0% SOC and > 0 < 0 MPH, 0s, NO ToDo
    7. RL5 = < 0 > 0% SOC and > 0 < 0 MPH, 0s, NO ToDo
    8. RL6 = < 0 > 0% SOC and > 0 < 0 MPH, 0s, NO ToDo

Troubleshooting

References

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