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PriusPlus-Electronic

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Revision as of 03:31, 1 December 2006 by 68.201.200.214 (talk) (→‎TODO)
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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".



File:EAA-PHEV-PRIUS-ControlBdSchematicV3r1 061116.png
These are the low power control board schematics from the latest PriusPlus conversion.



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.

TODO

Divide components between electonics and electrical categories:

  • Electronics

Control board, CAN-View, AH-meter?

  • Electrical

High power board, HV wiring, Battery charger, Heater/Charger relays

I'll put the wiring instructions for the control board and CAN-View under electronics unless someone protests.

  • CAN-View instructions for the V4 need to be added. I can update this by Dec.10 -Jim P.

Control Board

Overview

in pragmatic terms of inputs and outputs, link to theory

identify current sources of theory and condense into a few sentences here

show fully populated board

Assembly

show schematic

provide assmebly instructions: parts list, tools needed, estimated time

parts list is waiting to be scanned in.

Installation

what connects where. all the wiring taps first, refer to can-view and HV install guides. then refer to mechanical guide for physical installation into tray.

get better pictures of all the different connectors?

Troubleshooting

will need ron's input.

CAN-View & EV Mode button

Overview

Installation

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.

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. <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 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.
      7. Remove upper drivers side dash panel with power button, leave wires attached.
      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 grey 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 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, 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
  3. 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


assemble exact materials list, wires and lengths

Troubleshooting

References

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