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

Difference between pages "PriusPlus-RawData" and "Escape PHEV TechInfo"

From My wiki
(Difference between pages)
Jump to navigation Jump to search
(→‎Schematics: updated descriptions.)
 
 
Line 1: Line 1:
−
{{PriusPlus-Doc_Process}}
 
−
----
 
 
{{TOCright}}
 
{{TOCright}}
−
----
 
  
−
This page houses all raw materials which have been uploaded for various people to work with and incorporate into documentation on the other pages.  Add new documents to the list below and organize them if at all possible.
+
Technical information on the [[Ford_Escape_Hybrid | Ford Escape]] useful when designing a [[Escape PHEV]] conversion.
  
−
Image files can be easily linked to by placing a ":" after the "<nowiki>[[</nowiki>", otherwise the image will be shown.  If you want the image to appear then after the images name add "|thumb" to create a thumbnail for it, use "|200px" to specify a size other than the default, and use "|caption text" to describe the image as the last element before the closing "]]".
+
Unless otherwise noted, everything refers to a 2007 year model, belonging to [http://hybrids-plus.com/ Hybrids Plus].
  
−
Other non-image files such as .pdf, .doc, .xls, .etc can be linked to with the same "<nowiki>[[</nowiki>Image:" type link or with a <nowiki>[[</nowiki>Media:" link.  The :Image link will take you to the files page with a description of the file, list of pages on which it's used, and of course a link to the file itself.  The Media link will instead take you directly to that file without visiting the files page first.  See some examples in the "Intro Editing Help" section below.
 
  
−
==Files==
+
=Traction battery=
−
Here are the files that are available thus far.
 
  
−
===Schematics===
+
==Specs==
−
* High Power [[:Image:EAA-PHEV-PRIUS-HighPowerSchematic.png]][[Image:EAA-PHEV-PRIUS-HighPowerSchematic.png|25px]]
+
* Cells:  
−
* Control Board [[:Image:EAA-PHEV-PRIUS-ControlBdSchematic.png]][[Image:EAA-PHEV-PRIUS-ControlBdSchematic.png|25px]]
+
** 250 Sanyo NiMH cells
−
** Control Board [[:Image:EAA-PHEV-PRIUS-ControlBdSchematic.zip]] schematic created in [http://www.expresspcb.com ExpressSCH].
+
** 300 V nominal @ 1.2V/cell (Ford says 330V)
−
** Control Board [[:Image:EAA-PHEV-PRIUS-ControlBdPartsList.zip]] exported parts list from schematic in Excel format.
+
** 5.5 Ah
−
* LED Board [[:Image:EAA-PHEV-PRIUS-LEDBdSchematic.png]][[Image:EAA-PHEV-PRIUS-LEDBdSchematic.png|25px]]
+
* Electronics:  
−
** LED Board [[Image:EAA-PHEV-PRIUS-LEDBdSchematic.zip]] schematic created in [http://www.expresspcb.com ExpressSCH].
+
** controller
−
** LED Board [[Image:EAA-PHEV-PRIUS-LEDBdPartsList.zip]] exported parts list from schematic in Excel format.
+
** DC-DC converter to charge traction battery from 12 V battery ("Jump Start")
 +
** Contactors and pre-charge relay / resistor
 +
** Current sensor
 +
** Blowers
 +
* Connectors:
 +
** 12 V power and control (40 circuits)
 +
** HV (4 circuits)
 +
** AC/DC (2 circuits, unused)
  
−
===Photos===
+
==Removal==
−
You can browse the [http://www.eaa-phev.org/index.php?title=Special:Newimages entire gallery] of images here at the eaa-phev site, or visit some other galleries with potentially applicable photos:
+
 
−
* [[Maker_Faire_Photos]]
+
From the hatch opening:
−
* [[PiPrius#Photos]]
+
* Remove the carpet in the hatch compartment floor, to reveal the battery
−
** [[WhiteBird#Photos]]
+
* Turn the orange safety plug from LOCK to UNLOCK and pull it out
−
** [[GrayPerl#Photos]]
+
* Remove the black plastic air coupling on the rear-left
 +
* Remove the bolts on either side of the battery (3 bolts on each side)
 +
* Lift the bottom of the rear-right passenger seat and move it forward
 +
* List the strip of carpet to reveal the metal cover over the high voltage cables
 +
* Remove the 2 (not 3) nuts holding the black metal cover
 +
* Flip the seat forward to see the other end of the black metal cover
 +
* Remove the 2 bolts holding the other end of the black metal cover to the battery
 +
* Disconnect the battery:
 +
** From the rear right seat, remove the orange HV connector on the right (flip the lever)
 +
** From the rear left seat, remove the big black signal connector on the left (unbolts with a 10 mm socket wrench)
 +
** From the rear left seat, remove the small connector next to the signal connector (snaps)
 +
* Remove the battery
 +
** Remove the 6 bolts, 3 on each side of the battery, bolting it to the floor (1/2" socket)
 +
** Hook an engine hoist to the two round holes in the black metal on either side of the battery
 +
** Hoist the battery out of the car
 +
 
 +
<gallery>
 +
Image:batterypack-out.jpg|Battery pack lifted out of vehicle
 +
Image:trunk-sans-battery.jpg|Trunk after the battery was removed
 +
</gallery>
 +
 
 +
To open the battery:
 +
* You need a #35 security Torx driver, and a #35 Torx driver
 +
* Remove all the screws in the 2 top covers:
 +
** Cover over the fans
 +
** Cover over the batteries and electronics
 +
 
 +
<gallery>
 +
Image:batterypack-open1.jpg|Battery pack opened, rear view
 +
Image:batterypack-open2.jpg|Battery pack opened, front view
 +
</gallery>
 +
 
 +
==Component locations==
 +
[[Image:batterypack_locations.jpg|thumb|Component locations]]
 +
 
 +
The battery includes (as seen when in the vehicle):
 +
*Air blowers in the rear compartment
 +
*NiMH cells in the center
 +
**2 layers of cells
 +
**each layer in a left and right group
 +
**each group has 13 columns of 5 cells in series
 +
**total: 2 * 2 * 13 * 5 = 260 cells
 +
**pack voltage: 1.3 V * 260 = 338 V
 +
*controller on the right side
 +
*contactors and HV connector on the right-front corner
 +
*safety plug on the left-right corner
 +
*the Converter on the left side
 +
 
 +
==Block diagram==
 +
[[Image:battery_block_diag.gif|thumb||right|Block diagram of battery]]
 +
This block diagram shows the main components of the battery pack, and how they interface to the vehicle
 +
 
 +
*The NiMH cells store energy
 +
*The battery controller controls the battery pack
 +
**It communicates with the vehicle through the CAN bus
 +
**It monitors the air intake temperature, it controls the intake air flow and source, and it drives to DC blowers to blow air into the cells
 +
**It monitors the cells' voltage, including in intermediate points of the pack ("taps")
 +
**...
 +
*The DC-DC converter receives power from the 12 V battery and boosts it up to 300 V, to charge the traction battery when it's dead and the user presses the Jump Start button (by the driver's left foot)
 +
*The Safety Disconnects opens the pack mid-voltage
 +
*The HV Output section
 +
** It has a connector with 2 high-current contacts to connect the battery voltage to the vehicle
 +
** It has a pair of wires to determine if that connector is connected or not
 +
** It has contactors (high power relays) to connect or isolate the pack voltage
 +
*The blower compartment has 2 DC blowers to blow air into the cells
 +
 
 +
==Wiring diagram==
 +
[[Image:battery_wiring_diag.gif|thumb||right|Wiring diagram of battery.]]
 +
This wiring diagram shows how the components of the battery pack are wired together.
 +
 
 +
*High voltage wires are red.
 +
*Connectors are marked with their color and the number of positions
 +
*Sets of wires are shown together. The slash at one end indicates the number of wires
 +
*The function of sets of wires is shown above the wire
 +
*The wire colors are shown below the set of wires
 +
*Shaded squares indicate that wires are bundled together
 +
*The orientation of the components is shown as seen when looking from the hatch
 +
 
 +
This reverse engineering drawing is not guaranteed to be accurate and is offered as-is. Please direct corrections to [[User:DavideAndrea|DavideAndrea]].
 +
 
 +
==Connectors==
 +
[[Image:batterypack-data-conn.jpg|thumb||right|AC/DC connector (left) & Control connector (right)]]
 +
 
 +
The battery has 3 connectors, with a total of 34 wires:
 +
* C4227A - 28 wires - control
 +
* C4227B - 2 wires - low power HV to the AC/DC converter
 +
* C4227C - 4 wires - traction HV, interlock signals
 +
 
 +
===AC/DC converter connector: C4227B===
 +
[[Image:acdc_connector_cable.gif]]
 +
[[Image:acdc_connector_battery.gif]]
 +
 
 +
Pin-out. Looking into cable (left) and looking into battery (right)
 +
 
 +
The AC/DC converter connector has 2 circuits, with the following names and functions.
 +
 
 +
{| cellspacing=0 cellpadding=3 border=1
 +
|-
 +
| '''Group'''
 +
| '''Ckt'''
 +
| '''Pin(s)'''
 +
| '''Ext. color'''
 +
| '''Int. color'''
 +
| '''Name'''
 +
| '''Function'''
 +
| '''Notes'''
 +
|
 +
 
 +
|-
 +
|rowspan=2| AC/DC converter in
 +
| 3000
 +
| 1
 +
| Vio
 +
| Red
 +
| AC/DC in+
 +
|rowspan=2| To connect a 115 Vac charger for the traction battery?
 +
|rowspan=2| Ends in hood, by coolant tanks, unconnected and capped
 +
|bgcolor="red" | ??
 +
 
 +
|-
 +
| 3001
 +
| 1
 +
| VioOrg
 +
| Blk
 +
| AC/DC in-
 +
|bgcolor="red" | ??
  
−
{|
 
−
| valign=top | [[Image:100_1183.JPG|thumb|Photo of OEM NiMH battery with case fully removed during [[Inaugural Maker Faire|Maker Faire]], which is no longer necessary during current conversions.]]
 
−
| valign=top | [[Image:100_1176.JPG|thumb|Photo of the [[PriusBlue]] HV Tie in at the time of the [[Inaugural Maker Faire|Maker Faire]], routed out of OEM battery case near service plug.]]
 
−
| valign=top | [[Image:100_1442.JPG|thumb|Photo of the [[PriusBlue]] HV Tie in later after [[PiPrius]] conversion, there is an additional unused wire on the neg(-) OEM contactor for use during "Genset mode"]]
 
 
|}
 
|}
  
−
====Rons Images====
+
This connector is on one end of a cable. The other end of the is cable capped, under the hood, on the right, in front of the 2 coolant tanks, fastened to its own harness.
−
* Build Team [[:Image:SvensConversionTeamPhotoWNames_061112.jpg]]
+
 
−
<gallery>
+
I don't know what is supposed to go in it: some option? I don't know if this is an input or an output. The name (A/C converter), the fact that inside the traction battery the wires are black and red, and the relatively small size of the wires in the cable outside the battery, suggest that it's for a high-voltage, low current, traction battery charger. Maybe Ford provides a box, with just a bridge rectifier, 115 Vac in and 180 Vdc out, to charge the traction battery from the wall. D'de
−
Image:SvensConversionTeamPhotoWNames_061112.jpg|Build Team Photo with labels
+
 
−
Image:P10370.JPG|Team Photo around Rons Prius.
+
===Control connector: C4227A===
−
Image:P10371.JPG|Team Photo around Rons Prius.
+
[[Image:control_connector_cable.gif]]
−
Image:P10372.JPG|Team Photo around Rons Prius.
+
[[Image:control_connector_battery.gif]]
 +
 
 +
Pin-out. Looking into cable (left) and looking into battery (right)
 +
 
 +
The big control connector has 24 circuits, with the following names and functions.
 +
 
 +
{| cellspacing=0 cellpadding=3 border=1
 +
|-
 +
| '''Group'''
 +
| '''Ckt'''
 +
| '''Pin(s)'''
 +
| '''Ext. color'''
 +
| '''Int. color'''
 +
| '''Name'''
 +
| '''Function'''
 +
| '''Notes'''
 +
|
 +
 
 +
|-
 +
|rowspan=6| 12V pwr
 +
| 57
 +
| 35,36,37
 +
| LtgrnBlk
 +
| Blk
 +
| Ground
 +
| Power ground
 +
|
 +
|bgcolor="green" | OK
 +
 
 +
|-
 +
| 570
 +
| 30,31
 +
| BlkWht
 +
| BlkWht
 +
| Ground
 +
| Signal ground
 +
|
 +
|bgcolor="green" | OK
 +
 
 +
|-
 +
| 3800
 +
| 4,5,6
 +
| LtgrnBlk
 +
| Red
 +
| +12 V
 +
| Power +12V
 +
| Always on
 +
|bgcolor="green" | OK
 +
 
 +
|-
 +
| 16
 +
| 10,11
 +
| +12 V
 +
| RedLtgrn
 +
| RedBlu
 +
| Low power +12V
 +
| Always on
 +
|bgcolor="green" | OK
 +
 
 +
|-
 +
| 3206
 +
| 19
 +
| LtgrnYel
 +
| TanRed
 +
| Voltage supplied in Start and Run
 +
| Receives 12 V when the ignition switch is in either the On or Start positions (even if engine is not running)
 +
| From the ignition switch. Overload protected
 +
|bgcolor="green" | OK
 +
 
 +
|-
 +
| 3997
 +
| 14
 +
| Dkgrn
 +
| Tan
 +
| Power sustain relay out
 +
| Receives 12 V when the ignition switch is in either the On or Start positions (even if engine is not running) and for 2 seconds after the ignition is turned off
 +
| Fed by the Powertrain Control Module's Power Relay, located in the Battery Junction Box. The Powertrain Control Module is located under the hood, in the rear-center
 +
|bgcolor="green" | OK
 +
 
 +
|-
 +
|rowspan=8| Air intake
 +
| 3703
 +
| 21
 +
| BrnWht
 +
| BlkBrn
 +
| Battery compartment thermistor signal
 +
|rowspan=2| Senses air intake temperature
 +
|rowspan=8| All are located inside the column at the rear-left corner of car, inside air intake ducts
 +
|bgcolor="gray" | n.a.
 +
 
 +
|-
 +
| 3704
 +
| 25
 +
| DkgrnWht
 +
| WhtBlk
 +
| Battery compartment thermistor return
 +
|bgcolor="gray" | n.a.
 +
 
 +
|-
 +
| 698
 +
| 34
 +
| Red
 +
| RedBlu
 +
| Mode door actuator motor +
 +
|rowspan=2| Moves a flap controlling air flow
 +
|bgcolor="gray" | n.a.
 +
 
 +
|-
 +
| 699
 +
| 26
 +
| Org
 +
| BlkYel
 +
| Mode door actuator motor -
 +
|bgcolor="gray" | n.a.
 +
 
 +
|-
 +
| 1129
 +
| 17
 +
| BrnWht
 +
| RedGRn
 +
| Mode door actuator potentiometer +
 +
|rowspan=3| Senses position of flap
 +
|bgcolor="gray" | n.a.
 +
 
 +
|-
 +
| 1130
 +
| 20
 +
| PnkLtgrn
 +
| BluBlk
 +
| Mode door actuator potentiometer wiper
 +
|bgcolor="gray" | n.a.
 +
 
 +
|-
 +
| 1128
 +
| 24
 +
| GryLtBlu
 +
| BlkWht
 +
| Mode door actuator potentiometer -
 +
|bgcolor="gray" | n.a.
 +
 
 +
|-
 +
| 698
 +
| 34
 +
| Red
 +
| RedBlu
 +
| Zone Valve
 +
| Solenoid selecting air source
 +
|bgcolor="gray" | n.a.
 +
 
 +
|-
 +
|rowspan=2| CAN BUS
 +
| 1908
 +
| 29
 +
| Wht
 +
| YelRed
 +
| High speed CAN bus +
 +
|rowspan=2| Communicates with vehicle
 +
|rowspan=2| See CAN section below for messages
 +
|bgcolor="green" | OK
 +
 
 +
|-
 +
| 1909
 +
| 28
 +
| Blk
 +
| YelWht
 +
| High speed CAN bus -
 +
|bgcolor="green" | OK
 +
 
 +
|-
 +
|rowspan=2| Jump start switch
 +
| 176
 +
| 16
 +
| PnkLtgrn
 +
| BrnWht
 +
| Jump start switch feed
 +
| When grounded, lets 12 V battery jump charge-up the traction battery a bit, through DC-DC converter in battery pack, enough to start the car
 +
|rowspan=2| The switch is located to the left of the driver's left ankle, behind a black plastic panel
 +
|bgcolor="green" | OK
 +
 
 +
|-
 +
| 179
 +
| 12
 +
| OrgRed
 +
| GrnBlk
 +
| Jump start switch illumination +
 +
| When at 12 V, it lights-up the switch
 +
|bgcolor="green" | OK
 +
 
 +
|-
 +
|rowspan=4| Emergency control
 +
| 3003
 +
| 8
 +
| VioWht
 +
| Tan
 +
| Battery power off signal
 +
| 0-12 V square wave, 50% duty cycle, generated by battery. If all OK, 2 Hz. If problem, 5 Hz?
 +
| The Power Train Control Module is located under the hood, in the rear-center
 +
|bgcolor="green" | OK
 +
 
 +
|-
 +
| 877
 +
| 7,23
 +
| Wht
 +
| RedBlk
 +
| Fuel pump feed / Inertia Sw input
 +
| Normally receives 12 V when the ignition switch is in either the On or Start positions (even if engine is not running) and for 2 seconds after the ignition is turned off; no voltage when the ignition is off, or in case a crash opens an inertia switch
 +
| The High Voltage Cutoff switch is located in the right-rear column of the car
 +
|bgcolor="green" | OK
 +
 
 +
|-
 +
| 212
 +
| 27
 +
| Dkblu
 +
| BlkBlu
 +
| Immediate shutdown 1
 +
|rowspan=2| The Transaxle Control Module tells the battery to remove power to the vehicle?
 +
|rowspan=2| The Transaxle Control Module is under the hood, in the center, to the left of the box labeled "HYBRID"
 +
|bgcolor="green" | OK
 +
 
 +
|-
 +
| 213
 +
| 13
 +
| DkbluYel
 +
| BlkRed
 +
| Immediate shutdown 2
 +
|bgcolor="green" | OK
 +
 
 +
|-
 +
|rowspan=2| Unused
 +
|rowspan=2| n.a.
 +
| 18
 +
|rowspan=2| n.a.
 +
| TanRed
 +
|rowspan=2| ???
 +
|rowspan=2| ???
 +
|rowspan=2| Connected to controller, not used in vehicle
 +
|bgcolor="red" | ??
 +
 
 +
|-
 +
| 32
 +
| YelBlk
 +
|bgcolor="red" | ??
 +
 
 +
|}
 +
 
 +
Notes
 +
* Green OK: function is understood and confirmed
 +
* Red ??: function is not understood, or not yet confirmed
 +
* Gray n.a.: PHEV conversion can work without this function
  
−
Image:P10363.JPG|The unmodified trunk area.
+
===HV connector: C4227C===
−
Image:P10364.JPG|Pair of PVC air vents installed in spare tire well.
+
[[Image:batterypack-power-conn.jpg|thumb||right|HV connector]]
−
Image:P10365.JPG|Mockup of the Electronics housing for wiring and circuit boards.
+
[[Image:HV_connector_cable.gif]]
−
Image:P10373.JPG|The empty new battery box.
+
[[Image:HV_connector_battery.gif]]
  
−
Image:P10374.JPG|Electronics housing and misc parts on top of new battery box, ready for installation.
+
Pin-out. Looking into cable (left) and looking into battery (right)
−
Image:P10382.JPG|Electronics housing and battery box fitting mockup.
 
−
Image:P10389.JPG|Electronics housing semi-populated and battery box fitting mockup.
 
−
Image:P10385.JPG|Electronics housing semi-populated.
 
  
−
Image:P10386.JPG|Electronics housing semi-populated.
 
−
Image:P10387.JPG|Electronics housing semi-populated.
 
−
Image:P10393.JPG|Wire Taps into OEM contactor controls.
 
−
Image:P10394.JPG|Wire Taps into OEM contactor controls.
 
  
−
Image:P10380.JPG|Electronics housing (front).
+
The HV connector has 4 circuits, with the following names and functions.
−
Image:P10379.JPG|Electronics housing (bottom).
 
−
Image:P10377.JPG|Electronics housing (back).
 
−
Image:P10376.JPG|Electronics housing (top).
 
  
−
Image:P10366.JPG|Electronics in Rons Prius.
+
{| cellspacing=0 cellpadding=3 border=1
−
Image:P10367.JPG|Electronics in Rons Prius.
+
|-
−
Image:P10368.JPG|Electronics in Rons Prius.
+
| '''Group'''
−
Image:P10369.JPG|Electronics in Rons Prius.
+
| '''Ckt'''
 +
| '''Pin(s)'''
 +
| '''Ext. color'''
 +
| '''Int. color'''
 +
| '''Name'''
 +
| '''Function'''
 +
| '''Notes'''
 +
|
  
−
Image:P10381.JPG|Working on Circuit boards.
+
|-
−
Image:P10383.JPG|Populating Electronics housing.
+
|rowspan=2| HV
−
Image:P10384.JPG|Populating Electronics housing.
+
| 3180
−
Image:P10403.JPG|Electronics housing cooling fan flaps.
+
| +
 +
| Org
 +
|rowspan=2| n.a.
 +
| HV+
 +
|rowspan=2| Battery power
 +
|rowspan=2| To Transaxle Control Module
 +
|bgcolor="green" | OK
  
−
Image:P10390.JPG|Bracket for ABS control.
+
|-
−
Image:P10391.JPG|Bracket for ABS control.
+
| 3181
−
Image:P10395.JPG|Bracket for ABS control.
+
| -
−
Image:P10396.JPG|Bracket for ABS control.
+
| Org
 +
| HV-
 +
|bgcolor="green" | OK
  
−
Image:P10397.JPG|Delta-Q Charger installed.
+
|-
−
Image:P10398.JPG|Delta-Q Charger installed.
+
|rowspan=2| Interlock
−
Image:P10400.JPG|110v breakout quad and 110 to 12v power supply.
+
| 3130
−
Image:P10402.JPG|Ah Meter.
+
| 1
 +
| Gry
 +
| Blu
 +
| Traction Battery Control Module Interlock +
 +
|rowspan=2| Detects if HV connector is mated. The battery and the Transaxle Control Module both look at the voltage at these pins.
 +
|rowspan=2| To Transaxle Control Module
 +
|bgcolor="green" | OK
  
−
Image:P10405.JPG|Electronics Board.
+
|-
−
Image:P10406.JPG|Electronics Board.
+
| 3181
−
Image:P10407.JPG|Electronics Board.
+
| 2
−
Image:P10408.JPG|Electronics Board.
+
| Red
 +
| Wht
 +
| Traction Battery Control Module Interlock -
 +
|bgcolor="green" | OK
  
−
Image:P10404.JPG|Inside corner of battery box top.
+
|}
−
Image:P10409.JPG|[[CAN-View]] screen.
+
 
−
</gallery>
+
==Electronic Components==
  
−
====Photos from Chris Ewert's Conversion====
 
 
<gallery>
 
<gallery>
−
Image:Cutting Aluminum.JPG|Cutting the aluminum with a hacksaw
+
Image:batterypack_controller.jpg|The controller
−
Image:Tray Pieces.JPG|All the pieces necessary for the battery trays
+
Image:batterypack_controller_open.jpg|The controller, opened. The low voltage board is at the bottom, the high voltage one at the top
−
Image:Tray Parts Laid Out.JPG|All the parts from the tray laid out
+
Image:batterypack_converter.jpg|The Jump Start Converter
−
Image:Tray Set Together With Battery.JPG|Battery tray just set together
 
−
Image:Tray Set Together Close Up.JPG|Close up of the battery tray just set together
 
−
Image:Tray Ready for Jig.JPG|Tray set together, ready for creating "jig"
 
−
Image:Making Tray Jig Step 1.JPG|Starting to assemble the jig
 
−
Image:Making Tray Jig Step 2.JPG|More assembling the jig
 
−
Image:Making Tray Jig Step 3.JPG|Getting the jig assembled
 
−
Image:Almost Finished Tray Jig.JPG|Mostly finished tray jig
 
−
Image:Dremel Drill Press.JPG|Dremel drill press used for drilling holes in angle irons
 
−
Image:Holes drilled in aluminum.JPG|Holes drilled in the aluminum, then countersunk
 
−
Image:Closeup of Sample Finished Corner.JPG|Sample corner finished (done on scrap aluminum)
 
−
Image:Screws Sticking Through Partially Assembled Tray.JPG|Shows the self threading screws sticking out
 
−
Image:Finished Tray.JPG|The finished tray
 
−
Image:4 Finished Trays.JPG|All 4 finished trays laid out like they will be
 
−
Image:2 Trays with Some Supports.JPG|Experimenting with the support angle irons
 
−
Image:Starting on the Top of Battery Box.JPG|Starting on the top of the battery box
 
−
Image:Top Battery Box 45 Degree Cuts.JPG|45 degree angles cut in angle irons
 
−
Image:Top Battery Box With Corner Bracket.JPG|Corner bracket just set on the top
 
−
Image:Batt Box Top 3 Angles.JPG|3 angle irons cut and just sitting on the box
 
−
Image:Plexiglass Shield.JPG|Shows the Plexiglass "shield" on the inside of the angle irons
 
−
Image:Batt Box with Bolt Down Angle.JPG|Partially assembled battery box - bolted on top, but not the sides
 
−
Image:Inside Corner.JPG|Inside of the corner of the battery box top
 
−
Image:Binding Posts Ground Down.JPG|Binding posts that I choose to use.  They worked, but they aren't part of the official conversion method
 
−
Image:Finished Corner.JPG|A completed corner, bolts in and have been ground off.
 
−
Image:Batt Box with Bolt Down Angle.JPG|Shows the angle iron that will be used to bolt down the top
 
−
Image:Mostly Finished Batt Box.JPG|Mostly finished battery box.  Still lacking the bolts in the center of the pack, holes for bolting the top down and holes in the frame
 
−
Image:Fuses and Holders.JPG|Fuses and holders
 
−
Image:Fuse in holder.JPG|A fuse in it's holder
 
−
Image:Bottom of JTN60060.JPG|Bottom of the fuse holder (for DIN rail mounting)
 
−
Image:EV200 Contactor.JPG|The Kilovac EV200 contactor
 
 
</gallery>
 
</gallery>
  
−
====Older PriusPlus Images====
+
==Battery HVAC system==
−
Coming soon some photos from Rons original [[PriusPlus History]] conversion which may still be applicable to this project...
+
[[Image:batterypack_airflow.jpg|thumb|Battery HVAC air flow<br><font color="violet">exhaust</font>, <font color="yellow">forced air flow</font>, <font color="cyan">outside air intake</font>, <font color="green">exhaust inside vehicle</font>]]
  
−
===General Reference Materials===
+
[[Image:batterypack_hvac.jpg|thumb|Battery HVAC]]
−
These are some other General Reference Materials we use elsewhere on the site.  This is also an example of how to use references within the page text.  See [[PiPrius conversion process]] for another example of a page with multiple reference tages. 
 
  
−
* Prius Dismantle Manual <ref>[[Media:Priusdisman.pdf]] from http://www.airlabcorp.com/Prius/priusdisman.pdf</ref>
+
The HVAC system controls the temperature of the NiMH cells in the traction battery.
  
−
* Stereo Installation, Dash Dismantle <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>
+
Its components are located:
 +
* in the rear-left column
 +
* in the traction battery itself
  
−
* Stereo Installation, Dash Dismantle <ref>[[Media:PriusXMradio3.2.pdf]] from https://www.metrotpn.com/documents/PDF%20Files/Prius/Eddie's%20XMRadio%20Install/PriusXMradio3.2.pdf</ref>
+
When used in a closed loop, air flows:
 +
* from the empty spaces in the battery pack
 +
* out of the rear-most grille in the rear-right corner of the battery pack
 +
* into a duct in the rear-right column of the vehicle
 +
* up the rear duct in that colums
 +
* through the Mode Door that controls the air flow (unconfirmed)
 +
* through the Zone Valve that selects the air source (unconfirmed)
 +
* forward through a heat exchanger
 +
* down the front duct
 +
* out of the rear-right column
 +
* into the front-most grille in the rear-right corner of the battery pack
 +
* into the battery pack
 +
* into 2 ducts, one for each blower
 +
* into 2 blowers, one for each duct
 +
* into each set of cells (left set for left blower, right for right)
 +
* through the cells and into the empty spaces in the battery pack
 +
* completing the cycle
  
−
* [[CAN-View]] install without Nav <ref>[[Media:CAN-View installNONAVwt.pdf]] Adapted from http://www.hybridinterfaces.ca/installNONAV.html</ref>
+
The heat exchanger is either chilled by the vehicle's air conditioning system, or heated by the vehicle's engine coolant
  
−
* [[CAN-View]] install with Nav <ref>[[Media:CAN-View installWNAVwt.pdf]] Adapted from http://www.hybridinterfaces.ca/installWNAV.html</ref>
+
When using outside air:
 +
* air is taken from a vent in the rear-right window
 +
* down a duct
 +
* flows through an air filter
 +
* through the Mode Door
 +
* into the heat exchanger
 +
* then following the same path as above
 +
Now that extra air has been taken into the system, air has to be let out of it
 +
* air from the pack flows into the rear duct
 +
* the Zone Valve opens, letting out air from the rear duct into the open space in rear-right column
 +
* from there, air flows into the rear storage area
  
−
* [[Prius EV Mode Button]] Installation <ref>[[Media:Prius-evbutton-install.pdf]] from http://www.calcars.org/prius-evbutton-install.pdf</ref>
 
  
−
* Factory EV Mode Button <ref>[[Media:FactoryEV.pdf]] from http://www.scubadivervideo.com/Files/factoryEV.pdf</ref>
 
  
−
You should be familiar with these reference materials and standard operating procedures around high voltages.
 
−
<references/>
 
  
−
===ToDo===
+
To monitor the temperature, thermistors are placed:
−
Stuff to be imported/uploaded:
+
* 1 in the rear-right ducts
 +
* 2 by the blowers, one for each blower
 +
* 2 in the left block of cells, 2 in the right block (unconfirmed)
  
−
==Intro Editing Help==
+
To control the air flow and temperature:
−
===File Specific Help===
+
* the blower's speed is variable
−
File link Examples, click the edit button for this section to see how it works.
+
* the Mode Door's position is continuously variable from closed to fully open
 +
* the Zone Valve selects the air source
  
−
====Text Links:====
+
==CAN bus messages==
 +
The battery communicates to the rest of the vehicle through the CAN bus.
 +
The
  
−
* Using :Image takes you to the Images description page:
+
* [http://www.kvaser.com/can/protocol/index.htm Kvaser] has a simple explanation of the CAN bus.
−
** [[:Image:EAA-PHEV-PRIUS-ControlBdSchematic.png]]
+
* [http://en.wikipedia.org/wiki/CAN_bus wikipedia article on the CAN bus]
−
* Using Media takes you directly to the file:
 
−
** [[Media:EAA-PHEV-PRIUS-ControlBdSchematic.png]]
 
−
* You can use a | to change the text of the link to something more descriptive.
 
−
** [[:Image:EAA-PHEV-PRIUS-ControlBdSchematic.png|Control Board]]
 
  
−
====Inline resized images:====
+
===CAN Tools===
 +
* A generic adapter between the CAN-bus and a PC. It is convenient to use a USB port, though the serial or parallel or Ethernet port may be used as well. Examples of USB adapters:
 +
** [http://www.peak-system.com/db/gb/pcanusb_gb.html Peak's PCAN-USB] also sold as the [http://www.c-a-n.com/canusb.html?source=goog&kw=can+usb&gclid=CJLw2ZGH-IUCFQmMCwodIHRbtw GridConnect's GC-CAN-USB]
 +
*** Note: disconnecting this product's USB cable seems to create significant problems for Windows XP (immediate shut-down, or even the "blue screen of death"). You must use the system tray's "Remove hardware" icon first.
 +
** [http://www.grifo.com/VARIE/Candip/uk_canUSB.htm Grifo's CANUSB]
 +
** [http://www.systec-electronic.com/html/index.pl/en_product_usb_canmodul Systec's USB-CANmodul]
 +
** [http://www.can232.com/ CAN232] is a CAN to RS232 device used by [http://www.vassfamily.net/ToyotaPrius/CAN/cindex.html Attila Vass] with his early [[Prius PHEV User Interfaces#My CAN Project|My CAN Project]].
 +
** The '''CAN-View''' should not be confused with this [http://www.rmcan.com/index.php?id=61&L=1 CANview] product (notice no dash in the name), which is a CAN to RS232 device.
  
−
25px[[Image:EAA-PHEV-PRIUS-ControlBdSchematic.png|25px]], 50px[[Image:EAA-PHEV-PRIUS-ControlBdSchematic.png|50px]], 150px[[Image:EAA-PHEV-PRIUS-ControlBdSchematic.png|150px]],
+
* These adapters have a DE-9 DSUB connector, so you'll also need an adapter to the Prius' OBD connector. For example:
 +
** [http://www.c-a-n.com/gc-can-cab-odb2.html GridConnect's CAN to OBD2 Cable]
 +
* The Prius' OBD (On Board Diagnostics) connector is located under the dashboard, below and to the right of the steering wheel, facing down. A.k.a.: Data Link Connector 3 (DLC3)
 +
*Alternatively, tap into the CAN bus directly. Use a short cable to the CAN adapter.
 +
** CAN -: black wire
 +
** CAN +: white wire
 +
** GND - chassis
  
−
300px[[Image:EAA-PHEV-PRIUS-ControlBdSchematic.png|300px]]
+
===CAN bus protocol===
  
−
====Thumbnails:====
+
* The CAN bus is active only when the vehicle is in on (Start or Run position of the ignition key), and for a few seconds after the vehicle is turned off.
 +
* baud rate: 500 kbits/s (if you use the wrong rate, the vehicle will complain and store a DTC fault until the DTC codes are cleared)
 +
* Standard: CAN 2.0A ("standard CAN", 11-bit identifier)
 +
* Remote frames: not used
 +
** this means all the data are volunteered and none are requested; that is, that every component on the vehicle broadcasts its data periodically; no component puts out requests for data
  
−
[[Image:EAA-PHEV-PRIUS-ControlBdSchematic.png|thumb|caption]]
+
===CAN bus messages===
 +
The CAN bus has only 24 messages.
  
−
* Thumbnail tag will embed the image inline such that text will wrap arround the image.  The image will be alligened to the right by default or can be forced with a "|center" or "|left" tag.  Thumbnails should also include some caption as their last "|caption element".  Notice that the image code is placed above this text so that the text and image begin at the same place.
+
This screen capture was taken with the ignition on On, engine off, on Hybrids Plus' Escape.
  
−
{{Clear}} The <nowiki>{{Clear}}</nowiki> template can be used to force empty white space after a thumbnail before continuing with the next block of text.
+
[[Image:AllCanMessages.gif | All the messages on the CAN bus]]
  
−
* A Second Example...
+
[http://hybrids-plus.com/pmwiki/uploads/Ext/EscapeCanMessages.xls Spreadsheet with all messages]
−
[[Image:EAA-PHEV-PRIUS-ControlBdSchematic.png|thumb|100px|left|Small On Left]]
 
−
[[Image:EAA-PHEV-PRIUS-ControlBdSchematic.png|thumb|100px|Small On Right]]
 
−
Thumbnail tag will embed the image inline such that text will wrap arround the image.  The image will be alligened to the right by default or can be forced with a "|center" or "|left" tag.  Thumbnails should also include some caption as their last "|caption element".  Notice that the image code is placed above this text so that the text and image begin at the same place.
 
−
'' Thumbnail tag will embed the image inline such that text will wrap arround the image.  The image will be alligened to the right by default or can be forced with a "|center" or "|left" tag.  Thumbnails should also include some caption as their last "|caption element".  Notice that the image code is placed above this text so that the text and image begin at the same place.''
 
−
''Thumbnail tag will embed the image inline such that text will wrap arround the image.  The image will be alligened to the right by default or can be forced with a "|center" or "|left" tag.  Thumbnails should also include some caption as their last "|caption element".  Notice that the image code is placed above this text so that the text and image begin at the same place.''
 
  
−
{{Clear}}
+
===Battery CAN messages===
  
−
====Raw Large====
+
These are the messages generated by the battery.
−
* The raw image will be shown in a large size so probably shouldn't be used within a document like this.  Rather visitors should click on a smaller image, thumbnail, or link to see the Images page, from there they can use a link to get the fill sized original image. [[Image:EAA-PHEV-PRIUS-ControlBdSchematic.png]]
 
  
−
===General Help===
+
The Battery ECU (Electronic Control Unit) broadcasts the following messages. In this table, numbers in parenthesis (#) refer to the notes just below the table. Names in parenthesis are hunches.
  
−
Intro Paragraph here maybe with a link to the main [[PriusPlus]] article, links to external sites can appear as formatted [http://www.calcars.com 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.
+
{| cellspacing=0 cellpadding=3 border=1
 +
|-
 +
|'''ID (hex)'''
 +
|'''Period<br>[ms] [[#1 | (1)]]'''
 +
|'''No of<br>data<br>bytes'''
 +
|'''byte 0'''
 +
|'''byte 1'''
 +
|'''byte 2'''
 +
|'''byte 3'''
 +
|'''byte 4'''
 +
|'''byte 5'''
 +
|'''byte 6'''
 +
|'''byte 7'''
  
−
==A Major Topic==
+
|-
−
Talking about the major topic.
+
|300h
 +
|10
 +
|5
 +
|colspan=2 | Current [[#2 | (2)]]
 +
|Voltage [[#3 | (3)]]
 +
|Flags [[#4 | (4)]]
 +
|00h
 +
|colspan=3 bgcolor="gray"|
 +
 
 +
|-
 +
|310h
 +
|100
 +
|7
 +
|constant [[#7 | (7)]]
 +
|constant [[#8 | (8)]]
 +
|constant [[#9 | (9)]]
 +
|constant [[#10 | (10)]]
 +
|Temperature [[#11 | (11)]]
 +
|(Charge Limit) [[#12 | (12)]]
 +
|(Discharge Limit) [[#13 | (13)]]
 +
|colspan=1 bgcolor="gray"|
 +
 
 +
|-
 +
|320h
 +
|100
 +
|5
 +
|00h
 +
|00h
 +
|Flags [[#15 | (15)]]
 +
|Flags  [[#16 | (16)]]
 +
|SOC [[#17 | (17)]]
 +
|colspan=3 bgcolor="gray"|
 +
 
 +
 
 +
|}
 +
 
 +
 
 +
Notes:
 +
*h = hex value; d = decimal value; b = binary value;
 +
 
 +
<br>1) <span id="1"></span> How often this message is repeated
 +
<br>2) <span id="2"></span> Battery current. Raw reading, relative to reading at 0 current (typically 0600h), positive when current is sourced out of the battery. 12 bits? Units: 25 mA. Range (if 12 bits & 25 mA): 100 A out to 35 A in. Examples (assuming that at 0 current the reading is 0600h):
 +
* 0FC4h: 100 A out
 +
* 0790h: 10 A out
 +
* 0628h: 1 A out
 +
* 0600h: 0 A
 +
* 05D8h: 1 A in
 +
* 0479h: 10 A in
 +
* 0000h: 38 A in
 +
<br>3) <span id="3"></span> Battery voltage. Relative to 180 V. Units: V. Range seen: 312 to 366 V. Examples:
 +
* 78h: 300 V
 +
* 96h: 330 V
 +
<br>4) <span id="4"></span> Byte of flags. If the specified item is active, the bit is 1. Else, it is 0. 0 = unused or unknown bit.
 +
{| cellspacing=0 cellpadding=3 border=1
 +
|-
 +
|'''bit'''
 +
|'''7'''
 +
|'''6'''
 +
|'''5'''
 +
|'''4'''
 +
|'''3'''
 +
|'''2'''
 +
|'''1'''
 +
|'''0'''
 +
 
 +
|-
 +
|'''function'''
 +
|0
 +
|0
 +
|0
 +
|Safety plug removed
 +
|0
 +
|Contactors on
 +
|Precharge relay on
 +
|0
 +
 
 +
|}
 +
<br>6) <span id="6"></span> Byte of flags. If the specified item is active, the bit is 1. Else, it is 0. 0 = unused or unknown bit.
 +
{| cellspacing=0 cellpadding=3 border=1
 +
|-
 +
|'''bit'''
 +
|'''7'''
 +
|'''6'''
 +
|'''5'''
 +
|'''4'''
 +
|'''3'''
 +
|'''2'''
 +
|'''1'''
 +
|'''0'''
 +
 
 +
|-
 +
|'''function'''
 +
|Safety plug removed
 +
|HV connector unplugged
 +
|0
 +
|0
 +
|0
 +
|0
 +
|0
 +
|0
 +
 
 +
|}
 +
<br>7) <span id="7"></span> unknown. Always 8Ch
 +
<br>8) <span id="8"></span> unknown. Always 78h
 +
<br>9) <span id="9"></span> unknown. Always 50h
 +
<br>10) <span id="10"></span> unknown. Always 3Ch
 +
<br>11) <span id="11"></span> Pack temperature, relative to - 90C. Units: C. Insufficient data points to confirm this. Examples:
 +
* 104 = 14 C
 +
* 90 = 0 C
 +
* 82 = -8 C
 +
<br>12) <span id="12"></span> Charge Current Limit or something related to temperature? When first turned on, this item starts at a value, then drifts down to another value and stops. Turn off, turn on, and the item restarts at the same value where it started before. The values are very similar to the Temperature values. Needs more study.
 +
[[Image:escape_reported_vs_actual_soc.gif|thumb||right|Discharge Current Limit vs SOC]]
 +
<br>13) <span id="13"></span> Probably Discharge Current Limit. Units: A? Range seen: 75 to 155. Related to the actual State of Charge according to the graph on the right, and these approximate formulas:<br>
 +
* SOC< 138: value = 1.57 * SOC- 70
 +
* 138 < SOC< 157: value = 103 + 0.33 * SOC
 +
* SOC> 157: value = 155
 +
<br>15) <span id="15"></span> Byte of flags. If the specified item is active, the bit is 1. Else, it is 0. 0 = unused or unknown bit.
 +
{| cellspacing=0 cellpadding=3 border=1
 +
|-
 +
|'''bit'''
 +
|'''7'''
 +
|'''6'''
 +
|'''5'''
 +
|'''4'''
 +
|'''3'''
 +
|'''2'''
 +
|'''1'''
 +
|'''0'''
 +
 
 +
|-
 +
|'''function'''
 +
|Safety plug removed
 +
|HV connector unplugged
 +
|0
 +
|0
 +
|0
 +
|0
 +
|0
 +
|0
 +
 
 +
|}
 +
<br>16) <span id="16"></span>Byte of flags. If the specified item is active, the bit is 1. Else, it is 0. 0 = unused or unknown bit.
 +
{| cellspacing=0 cellpadding=3 border=1
 +
|-
 +
|'''bit'''
 +
|'''7'''
 +
|'''6'''
 +
|'''5'''
 +
|'''4'''
 +
|'''3'''
 +
|'''2'''
 +
|'''1'''
 +
|'''0'''
 +
 
 +
|-
 +
|'''function'''
 +
|0
 +
|0
 +
|0
 +
|0
 +
|0
 +
|0
 +
|0
 +
|All OK: HV connector is plugged, Safety Plug is in
 +
 
 +
|}
 +
[[Image:escape_soc_plot.gif|thumb||right|SOC vs time, parked]]
 +
<br>17) <span id="16"></span> State of Charge. Units: mAh. Range seen: 93 to 207 mAh. When stopped, and charging, the engine stops when the SOC level reaches DEh (111 mAh) and starts when the SOC drops to BDh (189 mAh)
  
−
===Sub Topic===
 
−
Yes, this is a sub topic
 
  
−
===Sub Topic number two===
+
{{Disclaimer}}
−
You guessed it, another sub topic.
 
  
−
==References==
+
[[Category:PHEV]]
−
<references/>
+
[[Category:Escape]]
 +
[[Category:EscapePHEV]]
 +
[[Category:Hybrids-Plus]]

Revision as of 00:15, 15 January 2007

Technical information on the Ford Escape useful when designing a Escape PHEV conversion.

Unless otherwise noted, everything refers to a 2007 year model, belonging to Hybrids Plus.


Traction battery

Specs

  • Cells:
    • 250 Sanyo NiMH cells
    • 300 V nominal @ 1.2V/cell (Ford says 330V)
    • 5.5 Ah
  • Electronics:
    • controller
    • DC-DC converter to charge traction battery from 12 V battery ("Jump Start")
    • Contactors and pre-charge relay / resistor
    • Current sensor
    • Blowers
  • Connectors:
    • 12 V power and control (40 circuits)
    • HV (4 circuits)
    • AC/DC (2 circuits, unused)

Removal

From the hatch opening:

  • Remove the carpet in the hatch compartment floor, to reveal the battery
  • Turn the orange safety plug from LOCK to UNLOCK and pull it out
  • Remove the black plastic air coupling on the rear-left
  • Remove the bolts on either side of the battery (3 bolts on each side)
  • Lift the bottom of the rear-right passenger seat and move it forward
  • List the strip of carpet to reveal the metal cover over the high voltage cables
  • Remove the 2 (not 3) nuts holding the black metal cover
  • Flip the seat forward to see the other end of the black metal cover
  • Remove the 2 bolts holding the other end of the black metal cover to the battery
  • Disconnect the battery:
    • From the rear right seat, remove the orange HV connector on the right (flip the lever)
    • From the rear left seat, remove the big black signal connector on the left (unbolts with a 10 mm socket wrench)
    • From the rear left seat, remove the small connector next to the signal connector (snaps)
  • Remove the battery
    • Remove the 6 bolts, 3 on each side of the battery, bolting it to the floor (1/2" socket)
    • Hook an engine hoist to the two round holes in the black metal on either side of the battery
    • Hoist the battery out of the car

  • Battery pack lifted out of vehicle

  • Trunk after the battery was removed

To open the battery:

  • You need a #35 security Torx driver, and a #35 Torx driver
  • Remove all the screws in the 2 top covers:
    • Cover over the fans
    • Cover over the batteries and electronics

  • Battery pack opened, rear view

  • Battery pack opened, front view

Component locations

Component locations

The battery includes (as seen when in the vehicle):

  • Air blowers in the rear compartment
  • NiMH cells in the center
    • 2 layers of cells
    • each layer in a left and right group
    • each group has 13 columns of 5 cells in series
    • total: 2 * 2 * 13 * 5 = 260 cells
    • pack voltage: 1.3 V * 260 = 338 V
  • controller on the right side
  • contactors and HV connector on the right-front corner
  • safety plug on the left-right corner
  • the Converter on the left side

Block diagram

Block diagram of battery

This block diagram shows the main components of the battery pack, and how they interface to the vehicle

  • The NiMH cells store energy
  • The battery controller controls the battery pack
    • It communicates with the vehicle through the CAN bus
    • It monitors the air intake temperature, it controls the intake air flow and source, and it drives to DC blowers to blow air into the cells
    • It monitors the cells' voltage, including in intermediate points of the pack ("taps")
    • ...
  • The DC-DC converter receives power from the 12 V battery and boosts it up to 300 V, to charge the traction battery when it's dead and the user presses the Jump Start button (by the driver's left foot)
  • The Safety Disconnects opens the pack mid-voltage
  • The HV Output section
    • It has a connector with 2 high-current contacts to connect the battery voltage to the vehicle
    • It has a pair of wires to determine if that connector is connected or not
    • It has contactors (high power relays) to connect or isolate the pack voltage
  • The blower compartment has 2 DC blowers to blow air into the cells

Wiring diagram

Wiring diagram of battery.

This wiring diagram shows how the components of the battery pack are wired together.

  • High voltage wires are red.
  • Connectors are marked with their color and the number of positions
  • Sets of wires are shown together. The slash at one end indicates the number of wires
  • The function of sets of wires is shown above the wire
  • The wire colors are shown below the set of wires
  • Shaded squares indicate that wires are bundled together
  • The orientation of the components is shown as seen when looking from the hatch

This reverse engineering drawing is not guaranteed to be accurate and is offered as-is. Please direct corrections to DavideAndrea.

Connectors

AC/DC connector (left) & Control connector (right)

The battery has 3 connectors, with a total of 34 wires:

  • C4227A - 28 wires - control
  • C4227B - 2 wires - low power HV to the AC/DC converter
  • C4227C - 4 wires - traction HV, interlock signals

AC/DC converter connector: C4227B

Acdc connector cable.gif Acdc connector battery.gif

Pin-out. Looking into cable (left) and looking into battery (right)

The AC/DC converter connector has 2 circuits, with the following names and functions.

Group Ckt Pin(s) Ext. color Int. color Name Function Notes
AC/DC converter in 3000 1 Vio Red AC/DC in+ To connect a 115 Vac charger for the traction battery? Ends in hood, by coolant tanks, unconnected and capped ??
3001 1 VioOrg Blk AC/DC in- ??

This connector is on one end of a cable. The other end of the is cable capped, under the hood, on the right, in front of the 2 coolant tanks, fastened to its own harness.

I don't know what is supposed to go in it: some option? I don't know if this is an input or an output. The name (A/C converter), the fact that inside the traction battery the wires are black and red, and the relatively small size of the wires in the cable outside the battery, suggest that it's for a high-voltage, low current, traction battery charger. Maybe Ford provides a box, with just a bridge rectifier, 115 Vac in and 180 Vdc out, to charge the traction battery from the wall. D'de

Control connector: C4227A

Control connector cable.gif Control connector battery.gif

Pin-out. Looking into cable (left) and looking into battery (right)

The big control connector has 24 circuits, with the following names and functions.

Group Ckt Pin(s) Ext. color Int. color Name Function Notes
12V pwr 57 35,36,37 LtgrnBlk Blk Ground Power ground OK
570 30,31 BlkWht BlkWht Ground Signal ground OK
3800 4,5,6 LtgrnBlk Red +12 V Power +12V Always on OK
16 10,11 +12 V RedLtgrn RedBlu Low power +12V Always on OK
3206 19 LtgrnYel TanRed Voltage supplied in Start and Run Receives 12 V when the ignition switch is in either the On or Start positions (even if engine is not running) From the ignition switch. Overload protected OK
3997 14 Dkgrn Tan Power sustain relay out Receives 12 V when the ignition switch is in either the On or Start positions (even if engine is not running) and for 2 seconds after the ignition is turned off Fed by the Powertrain Control Module's Power Relay, located in the Battery Junction Box. The Powertrain Control Module is located under the hood, in the rear-center OK
Air intake 3703 21 BrnWht BlkBrn Battery compartment thermistor signal Senses air intake temperature All are located inside the column at the rear-left corner of car, inside air intake ducts n.a.
3704 25 DkgrnWht WhtBlk Battery compartment thermistor return n.a.
698 34 Red RedBlu Mode door actuator motor + Moves a flap controlling air flow n.a.
699 26 Org BlkYel Mode door actuator motor - n.a.
1129 17 BrnWht RedGRn Mode door actuator potentiometer + Senses position of flap n.a.
1130 20 PnkLtgrn BluBlk Mode door actuator potentiometer wiper n.a.
1128 24 GryLtBlu BlkWht Mode door actuator potentiometer - n.a.
698 34 Red RedBlu Zone Valve Solenoid selecting air source n.a.
CAN BUS 1908 29 Wht YelRed High speed CAN bus + Communicates with vehicle See CAN section below for messages OK
1909 28 Blk YelWht High speed CAN bus - OK
Jump start switch 176 16 PnkLtgrn BrnWht Jump start switch feed When grounded, lets 12 V battery jump charge-up the traction battery a bit, through DC-DC converter in battery pack, enough to start the car The switch is located to the left of the driver's left ankle, behind a black plastic panel OK
179 12 OrgRed GrnBlk Jump start switch illumination + When at 12 V, it lights-up the switch OK
Emergency control 3003 8 VioWht Tan Battery power off signal 0-12 V square wave, 50% duty cycle, generated by battery. If all OK, 2 Hz. If problem, 5 Hz? The Power Train Control Module is located under the hood, in the rear-center OK
877 7,23 Wht RedBlk Fuel pump feed / Inertia Sw input Normally receives 12 V when the ignition switch is in either the On or Start positions (even if engine is not running) and for 2 seconds after the ignition is turned off; no voltage when the ignition is off, or in case a crash opens an inertia switch The High Voltage Cutoff switch is located in the right-rear column of the car OK
212 27 Dkblu BlkBlu Immediate shutdown 1 The Transaxle Control Module tells the battery to remove power to the vehicle? The Transaxle Control Module is under the hood, in the center, to the left of the box labeled "HYBRID" OK
213 13 DkbluYel BlkRed Immediate shutdown 2 OK
Unused n.a. 18 n.a. TanRed ??? ??? Connected to controller, not used in vehicle ??
32 YelBlk ??

Notes

  • Green OK: function is understood and confirmed
  • Red ??: function is not understood, or not yet confirmed
  • Gray n.a.: PHEV conversion can work without this function

HV connector: C4227C

HV connector

HV connector cable.gif HV connector battery.gif

Pin-out. Looking into cable (left) and looking into battery (right)


The HV connector has 4 circuits, with the following names and functions.

Group Ckt Pin(s) Ext. color Int. color Name Function Notes
HV 3180 + Org n.a. HV+ Battery power To Transaxle Control Module OK
3181 - Org HV- OK
Interlock 3130 1 Gry Blu Traction Battery Control Module Interlock + Detects if HV connector is mated. The battery and the Transaxle Control Module both look at the voltage at these pins. To Transaxle Control Module OK
3181 2 Red Wht Traction Battery Control Module Interlock - OK

Electronic Components

  • The controller

  • The controller, opened. The low voltage board is at the bottom, the high voltage one at the top

  • The Jump Start Converter

Battery HVAC system

Battery HVAC air flow
exhaust, forced air flow, outside air intake, exhaust inside vehicle
Battery HVAC

The HVAC system controls the temperature of the NiMH cells in the traction battery.

Its components are located:

  • in the rear-left column
  • in the traction battery itself

When used in a closed loop, air flows:

  • from the empty spaces in the battery pack
  • out of the rear-most grille in the rear-right corner of the battery pack
  • into a duct in the rear-right column of the vehicle
  • up the rear duct in that colums
  • through the Mode Door that controls the air flow (unconfirmed)
  • through the Zone Valve that selects the air source (unconfirmed)
  • forward through a heat exchanger
  • down the front duct
  • out of the rear-right column
  • into the front-most grille in the rear-right corner of the battery pack
  • into the battery pack
  • into 2 ducts, one for each blower
  • into 2 blowers, one for each duct
  • into each set of cells (left set for left blower, right for right)
  • through the cells and into the empty spaces in the battery pack
  • completing the cycle

The heat exchanger is either chilled by the vehicle's air conditioning system, or heated by the vehicle's engine coolant

When using outside air:

  • air is taken from a vent in the rear-right window
  • down a duct
  • flows through an air filter
  • through the Mode Door
  • into the heat exchanger
  • then following the same path as above

Now that extra air has been taken into the system, air has to be let out of it

  • air from the pack flows into the rear duct
  • the Zone Valve opens, letting out air from the rear duct into the open space in rear-right column
  • from there, air flows into the rear storage area



To monitor the temperature, thermistors are placed:

  • 1 in the rear-right ducts
  • 2 by the blowers, one for each blower
  • 2 in the left block of cells, 2 in the right block (unconfirmed)

To control the air flow and temperature:

  • the blower's speed is variable
  • the Mode Door's position is continuously variable from closed to fully open
  • the Zone Valve selects the air source

CAN bus messages

The battery communicates to the rest of the vehicle through the CAN bus. The

CAN Tools

  • A generic adapter between the CAN-bus and a PC. It is convenient to use a USB port, though the serial or parallel or Ethernet port may be used as well. Examples of USB adapters:
  • These adapters have a DE-9 DSUB connector, so you'll also need an adapter to the Prius' OBD connector. For example:
  • The Prius' OBD (On Board Diagnostics) connector is located under the dashboard, below and to the right of the steering wheel, facing down. A.k.a.: Data Link Connector 3 (DLC3)
  • Alternatively, tap into the CAN bus directly. Use a short cable to the CAN adapter.
    • CAN -: black wire
    • CAN +: white wire
    • GND - chassis

CAN bus protocol

  • The CAN bus is active only when the vehicle is in on (Start or Run position of the ignition key), and for a few seconds after the vehicle is turned off.
  • baud rate: 500 kbits/s (if you use the wrong rate, the vehicle will complain and store a DTC fault until the DTC codes are cleared)
  • Standard: CAN 2.0A ("standard CAN", 11-bit identifier)
  • Remote frames: not used
    • this means all the data are volunteered and none are requested; that is, that every component on the vehicle broadcasts its data periodically; no component puts out requests for data

CAN bus messages

The CAN bus has only 24 messages.

This screen capture was taken with the ignition on On, engine off, on Hybrids Plus' Escape.

All the messages on the CAN bus

Spreadsheet with all messages

Battery CAN messages

These are the messages generated by the battery.

The Battery ECU (Electronic Control Unit) broadcasts the following messages. In this table, numbers in parenthesis (#) refer to the notes just below the table. Names in parenthesis are hunches.


ID (hex) Period
[ms] (1) 		No of
data
bytes 		byte 0 byte 1 byte 2 byte 3 byte 4 byte 5 byte 6 byte 7
300h 10 5 Current (2) Voltage (3) Flags (4) 00h
310h 100 7 constant (7) constant (8) constant (9) constant (10) Temperature (11) (Charge Limit) (12) (Discharge Limit) (13)
320h 100 5 00h 00h Flags (15) Flags (16) SOC (17)



Notes:

  • h = hex value; d = decimal value; b = binary value;


1) How often this message is repeated
2) Battery current. Raw reading, relative to reading at 0 current (typically 0600h), positive when current is sourced out of the battery. 12 bits? Units: 25 mA. Range (if 12 bits & 25 mA): 100 A out to 35 A in. Examples (assuming that at 0 current the reading is 0600h):

  • 0FC4h: 100 A out
  • 0790h: 10 A out
  • 0628h: 1 A out
  • 0600h: 0 A
  • 05D8h: 1 A in
  • 0479h: 10 A in
  • 0000h: 38 A in


3) Battery voltage. Relative to 180 V. Units: V. Range seen: 312 to 366 V. Examples:

  • 78h: 300 V
  • 96h: 330 V


4) Byte of flags. If the specified item is active, the bit is 1. Else, it is 0. 0 = unused or unknown bit.

bit 7 6 5 4 3 2 1 0
function 0 0 0 Safety plug removed 0 Contactors on Precharge relay on 0


6) Byte of flags. If the specified item is active, the bit is 1. Else, it is 0. 0 = unused or unknown bit.

bit 7 6 5 4 3 2 1 0
function Safety plug removed HV connector unplugged 0 0 0 0 0 0


7) unknown. Always 8Ch
8) unknown. Always 78h
9) unknown. Always 50h
10) unknown. Always 3Ch
11) Pack temperature, relative to - 90C. Units: C. Insufficient data points to confirm this. Examples:

  • 104 = 14 C
  • 90 = 0 C
  • 82 = -8 C


12) Charge Current Limit or something related to temperature? When first turned on, this item starts at a value, then drifts down to another value and stops. Turn off, turn on, and the item restarts at the same value where it started before. The values are very similar to the Temperature values. Needs more study.

File:Escape reported vs actual soc.gif
Discharge Current Limit vs SOC


13) Probably Discharge Current Limit. Units: A? Range seen: 75 to 155. Related to the actual State of Charge according to the graph on the right, and these approximate formulas:

  • SOC< 138: value = 1.57 * SOC- 70
  • 138 < SOC< 157: value = 103 + 0.33 * SOC
  • SOC> 157: value = 155


15) Byte of flags. If the specified item is active, the bit is 1. Else, it is 0. 0 = unused or unknown bit.

bit 7 6 5 4 3 2 1 0
function Safety plug removed HV connector unplugged 0 0 0 0 0 0


16) Byte of flags. If the specified item is active, the bit is 1. Else, it is 0. 0 = unused or unknown bit.

bit 7 6 5 4 3 2 1 0
function 0 0 0 0 0 0 0 All OK: HV connector is plugged, Safety Plug is in
SOC vs time, parked


17) State of Charge. Units: mAh. Range seen: 93 to 207 mAh. When stopped, and charging, the engine stops when the SOC level reaches DEh (111 mAh) and starts when the SOC drops to BDh (189 mAh)


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

Retrieved from "https://www.eaa-phev.org/wiki/index.php?title=PriusPlus-RawData&oldid=3926"