SYSTEMS. Hymotion'" LS Plug-In Conversion Module (PCM) User Guide

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1 SYSTEMS Hymotion'" LS Plug-In Conversion Module (PCM) User Guide

2 Copyright 2008 A 12JSystems, Inc. All rights reserved DOCUMENT NOTICE: The information contained in this manual is the propcny of A12JSystems. Inc ("A I23Syslcms") and is subject to change without notice. A I23Systcms reserves the right to make changes in the design of its products or components as progress in engineering and manufacturing may warrant. It is the customer's responsibility to satisfy itself as to whether the infonnation contained herein is adequate and sufficient for user's particular usc. It is the further responsibility ofeach user to ensure that all applications of A 123Systcms' products arc appropriate and safe based on conditions anticipated or encountered during usc. This document docs not creatc any additional obligation for A I23Systcms and docs not constitute additional warranties and representations. The A 12JSystems' logo is a trademark and a service mark of A 12JSystems, Inc. Release 1.0,

3 Contents Introduction to Hymotion11'l LS PCM Module Overview I-I L5 PCM Specifications 1-3 Perfonnance 1-4 Key Features 1-4 Tips to Improve your Fuel Economy 1-4 Gentle Acceleration to Minimize Use ofengine 1-4 ClimaleControl Use lhe Prius Display for Feedback \-5 General Vehicle Usage and Operations Overview 2-. Driving the Vehicle 2-1 Vehicle Load Precautions 2-1 Hymotion LS PCM Operation Overview 3-1 Generallnfonnation 3-2 Energy Monitor Display 3-2 State ofcharge Indicator 3-2 Charging the Vehicle 3-3 Important Notes on Charging 3-4 Service and Maintenance Overview 4-1 Charge Port 4-1 Tire Repair Option 4-1 User Guide

4 Chapter 1 Introduction to Hymotion LS PCM Module This chapter includes the following sections: Overview on page I-I LS PCM Specifications on page 1-3 Perfonnance on page 1-4 Key Features on page 1-4 Tips to Improve your Fuel Economy on page 1-4 Overview Your Toyota Prius has been modified to include an additional battery known as the Hymotion LS Plug-In Conversion Module (PCM). The Hymotion LS PCM, installed in the spare tire well as shown in Figure I-I, allows the Prius to use pure electric drive more often and for significantly longer distances, resulting in fuel efficiency gains over the standard Prius. User Guide 1-1

5 Chapter 1 Overview Introduction to Hymotion'M L5 PCM Module Figure 1-1 Hymotion L5 pem installed in a Prius The Hymotion L5 PCM uses power from a standard household electric outlet to recharge its battery. This provides the L5 PCM with approximately 5 kilowatt hours (kwh) ofenergy storage. With the L5 PCM installed, the Prius is capable ofachieving in excess of 100 miles per gallon (mpg), while propelling the vehicle with electrically assisted driving for distances of30 to 40 miles. 1-2 Release 1.0,

6 Chapter 1 Introduction to Hymotion'" LS PCM Module L5 PCM Specifications LS PCM Specifications Table 1-1. Specifications Battery Type Energy Charge tcmpe..ature range Operation temperature range Charge vouage Charge time Weight Uthlum Nanophosphate- Approximately 5kWh -30 dog C to 60 dog C -30 dog C to 60 dog C 120V (15A circuit) dog C 85 Kg User Guide 1-3

7 Chapter 1 Introduction to Hymotion'M LS PCM Module Performance Performance The L5 PCM perfonnance ratings are as follows: A 30 to 40 mile electrically assisted driving range when using a combination ofelectric power from the L5 PCM and gasoline. Up to 100 mpg (or greater) city/highway combined fuel economy within the 30 to 40 mile driving range of the L5 PCM. NOTE: Your fuel economy may vary. Please refer to Tips to lmprove your Fuel Economy on page 1-4 for ways to improve your fuel economy. After the L5 PCM has fully discharged, the only limitation on your vehicle's range is the amount offuel in your gas tank. Your Prius reverts to its original operation when the L5 PCM charge has been depleted. Key Features The L5 PCM key features are as follows: Integrates into your vehicle without removing the Prius battery module Vehicle resumes standard operation when the L5 PCM has fully discharged The Prius battery module level gauge indicates L5 PCM status An integrated crash sensor isolates the L5 PCM in a collision Integrated L5 PCM temperature monitoring Interlock feature to prevent drive off while charging Fully crash tested in accordance with National Highway Transportation and Safety Administration (NHTSA) regulations Maintains your vehicle's Super Ultra Low Emissions Vehicle (SULEV) emissions ratings Tips to Improve your Fuel Economy Gentle Acceleration to Minimize Use of Engine Gently accelerating your vehicle allows the gasoline engine to remain disengaged in many circumstances. 1-4 Release 1.0,

8 Chapter 1 Introduction to Hymotion'M L5 PCM Module Tips to Improve your Fuel Economy Accelerating the Prius with a gentle pulse ofthe accelerator and then allowing the vehicle to glide helps to disengage the gasoline engine. When the gasoline engine does engage, easing offthe accelerator to disengage and then using the pulse and glide technique will gain vehicle speed using electric power. Climate Control The gasoline engine is the only source ofheat for your vehicle. Using the heater as little as possible minimizes use ofthe gasoline engine. Use the cooling system on the highway, rather than opening the windows, to improve aerodynamic efficiency. Use the defroster control on the console display. The defroster control on the steering wheel always engages the gasoline engine. Use the Prius Display for Feedback The display indicates when the gasoline engine is engaged. Use this feedback and apply the pulse and glide technique to disengage the engine when possible. The Prius console displays the State ofcharge (SOC) ofthe L5 PCM, when it is active. User Guide 1-5

9 Chapter 2 General Vehicle Usage and Operations This chapter includes the following sections: Overview on page 2-1 Driving the Vehicle on page 2-1 Vehicle Load Precautions on page 2-1 Overview The changes required to add a Hymotion L5 PCM to the Toyota Prius are minimum. Operate and maintain your modified Prius as you would a standard Prius. Please refer to the Prius Owners Manual for vehicle operations and maintenance instructions. All vehicle maintenance and service intervals, as recommended by Toyota, should continue to be followed. Driving the Vehicle Having the Hymotion L5 PCM installed does not require any special driving techniques. The vehicle should be driven in the same manner as a standard Prius. Vehicle Load Precautions [jf NOTE Do not exceed the load limits outlined in your Prius OwnersManual. The additional weight ofthe Hymotion L5 PCM should be considered when adding cargo to the vehicle. It is recommended that large volumes of liquids are not transported in the trunk in order to prevent the possibility ofa spill. It could harm the L5 pem ifa large spill were to occur. User Guide 2-1

10 Chapter 3 Hymotion LS PCM Operation This chapter includes the following sections: Overview on page 3-1 General Information on page 3-2 Energy Monitor Display on page 3-2 State ofcharge Indicator on page 3-2 Charging the Vehicle on page 3-3 Important Noles on Charging on page 3-4 Overview The L5 PCM can be turned on or offat any point while the vehicle is operating. Change the dashboard switch to the up position for On or the down position for Off. See Figure 3-1 for the location and details of the switch. Figure 3-1 Location and details of the L5 PCM's On / Off switch User Guide 3-1

11 Chapter 3 Hymotion LS pem Operation Genera/Information General Information General information regarding the L5 PCM switch is as follows: When the L5 PCM switch is in the On position and the vehicle is in READY mode, the L5 PCM comes online if it has been sufficiently charged. When the L5 PCM switch is left in the On position, it automatically shuts off when the vehicle is turned off. When the L5 PCM is turned offor if it fully discharges while driving, the standard Prius operations resume. Energy Monitor Display When the L5 PCM is in operation, the Energy Monitor displays its State of Charge (SOC). The SOC is an indication of the L5 PCM's available capacity. When a new piece ofinformation is received, the display flickers. This is normal. The SOC indicator reflects standard Prius mode when the L5 PCM has fully discharged or has been turned off. figure 3-2 Energy Monitor display State of Charge Indicator Due to the interactions between the L5 PCM and the vehicle's display, the center panel can return to the Energy Monitor screen during L5 PCM information updates interrupting the user if they are browsing through other 3-2 Release 1.0,

12 Chapter 3 Hymotion LS PCM Operation Charging the Vehicle functions. For example, ifthe user is adjusting the temperature using the touch panel display, and the L5 PCM begins communication with the vehicle, the display screen returns to the Energy Monitor screen and overrides the user's temperature adjustment. It is normal to hear one or several short beeps when this happens. Figure 3-3 illustrates the SOC display. Figure 3-3 SOC indicator for Hymotion LS PC" Charging the Vehicle & CAUTION The Hymotion L5 PCM can be fully charged by using a common household electrical outlet. The eleclrical outlei must be capable ofproviding a dedicated 1.2 kw (approximalely loa) 10 the vehicle and must he equipped wilh Ground Fault Circuit Interruption (Grel). Use only the extension cord provided by A 123Systems. Do not install any products such as timers or measuring devices between the ourlet 3nd the A 123Systems extension cord. I. Verify the vehicle is turned off. 2. Plug the supplied A I23Systems extension cord into the vehicle's charge port located in the rear bumper. 3. It takes approximately 5 to 6 hours to charge a fully discharged L5 PCM. Figure 3-4 illustrates a vehicle's charge port. User Guide 3-3

13 Chapter 3 Hymotion L5 pem Operation Important Notes on Charging Figure 3-4 Vehicle charge port The brake lights illuminate for a duration of4 to 5 seconds after plugging in the vehicle. This indicates that a proper connection with the vehicle has been made. The brake lights then dim to about 30% intensity for the remainder of the charge cycle indicating the unit is accepting charge. Once the charge cycle is complete, the brake lights turn off. During the initial charging sequence the following can be observed: I. A series of relay clicks is heard from the L5 PCM. 2. After approximately 15 seconds, the cooling fan, in the L5 PCM, turns on providing the module with cool air while charging. 3. Several minutes into the charging phase, it is normal to hear a humming noise from within the battery module, indicating that electrical current is flowing into the battery pack. Important Notes on Charging To prevent the user from driving offwhile the vehicle is charging, the L5 PCM activates an interlock feature that deactivates the function of the vehicle POWER button. Ifthe vehicle must be moved during the charge cycle, disconnect the power source before vehicle operation. When reconnected, the L5 PCM continues the charge cycle. 3-4 Release 1.0,

14 Chapter 3 Hymotion L5 PCM Operation Important Notes on Charging The charge duration, for the L5 PCM, is approximately 5 to 6 hours. Typical power consumption for a fully discharged L5 PCM ranges between 5 and 6 kwh. This includes charging efficiency and the energy spent in balancing the L5 PCM. To safeguard the L5 PCM against over current, a circuit breaker is used to protect the battery and the electronics. The circuit breaker is located on the back side of the L5 PCM, and can be reset by depressing the white/red cylinder. The location and details ofthe circuit breaker are shown in Figure 3 5. Figure 3-5 Circuit breaker with exhaust manifold removed User Guide 3-5

15 Chapter 4 Service and Maintenance This chapter includes the following sections: Overview on page 4-1 Charge Port on page 4-1 Tire Repair Option on page 4-1 Overview [It NOTE The Prius should be serviced and maintained in accordance to the guidelines recommended in the Prius Owners Manual. The Hymotion L5 PCM does not need to be disconnected or isolated from the vehicle for service to occur. lfa red triangle is displayed on the dashboard ofyour vehicle, a service technician must be contacted. Charge Port If the ground terminal on the bumper charge port has any evidence of corrosion, a service technician should be contacted. The L5 pem should not be charged until the situation is resolved. The corroded terminals leads to an unsafe condition in the event that a short circuit to chassis fault occurs. Tire Repair Option A spare tire sealant and inflator kit is a fast and efficient way to fix a tire if there has not been significant damage to the tire. There is no need to jack up the car or remove the wheel. To repair a tire using a tire sealant and inflator kit: I. Install the tire sealant. User Guide 4-1

16 Chapter 4 Service and Maintenance Tire Repair Option 2. Plug in the air compressor. 3. Tum on the air compressor and inflate the tire. NOTE: Follow all directions on the tire sealant and inflator kit. These products cannot be used ifthe tire has significant damage. 4-2 Release 1.0,

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