This gentleman is a world class teacher. I don't have a Prius, but after stumbling apon this video I just had to subscribe. The way the information is relayed to the viewing audience is as high a quality as the engineering in question. Respect.
You encouraged me to work on inverter/converter unit on my 2007 Prius. Dealership wanted to charge me 5k for it but it cost me $300 on used unit. My Prius is almost 277, 000 miles and counting!!!! Thank you so much.
Was it hard do it ,my 2012 Prius converter with bad at 122,000 miles . It still had warranty I save $4200. I got 4 years more of warranty or 30,000 miles more until warranty ends lol
Good Morning! I am a Brazilian automotive specialist graduated from SENAI and General Motors Brasil! Weber, congratulations, excellent technical video! May God bless you and keep making other videos with this technical ability! Grateful Wilmar Ribeiro
You are absolutely brilliant, wonderful and very intelligent and calm person sir. This is absolutely free knowldge you are providing us. I am very grateful to you. I wish that i could be in your class to learn from you. I thank you so much for making all these videos.
I do not know English very well, but I've seen many videos of you. You are an excellent and extremely professional teacher. For 3 or 4 years I subscribed to your channel and I liked all the videos I've seen. I work the electronics of the cars. I know something about robotics, mechanics, electronics. I think cars are robot with wheels. I like the electrics and I think the hybrids are a step to them and until the infra-structure is created so that we can all have an electric car, the hybrids are good. I had a 2006 Honda Civic Hibrid. I bought it in 250 dollars because they were going to join it. In a few hours I put it to work. Now I have a 2006 Toyota Prius. It does not work With what little I've seen, I've learned that it's very different from Honda. It has helped me a lot to see all your videos of the Toyotas II Generation. The high voltage batteries had 190 volts. They had a lot of sulfate in the contacts. I cleaned everything very well and now it has 201 volts. The scanner gives me two codes: 1) on the HV and it tells me to replace the Inverter-converter module. 2) Replace the battery. When I try to start the relay of the battery block sounds and in the dash it flashes READY 2 or 3 times and then the red triangle appears. I have another module inverter converter equal, but my question is whether it is the module or the batteries. I measure the voltage of them at the moment of starting and lowering something, but in a few seconds they return to 201 volts. I also want to know if the starter of this car is only for the MG1 or has an external one. I already learned with you that it has no alternator, which it does through the conversion of 201.6 to 12 in the inverter module of the A / C. I know that the Honda does have a starter, but it still does not. Please, I need your help. You can answer me in English and I use the google translator, but if you can send me some documentation in Spanish I would also appreciate it. Thank you very much for all your videos. I'm sure you help thousands of people around the world, because you do it with professionalism and love of what you do. Greetings from Tampa, Florida.
Thank you, There is no starter, MG1 starts the engine. It sounds like you still have a battery problem. The converter trouble code is not a good sign either. Best wishes
This teaching setup is incredible! Thank you so much for taking the time to share this information us. The prius is such an incredible vehicle and this layout showcases the components so well!
Excellent Video!! Thank You!. at 17:30 to 18:00 Min, how much current is the DC to DC 12 volt battery supply capable of producing at 12-14.5 Volts? I want to hook up a 120 Volt power inverter to the 12 volt battery in the back.
100 amps, but the car uses up to 78 amps with the engine running. Not much left for an inverter. The 12V battery will make up the rest as it slowly goes dead. See th-cam.com/video/_V9PiOpaxyE/w-d-xo.html
Thanks John! I'm thinking to buy an used 2nd gen Prius and with no knowledge on the area, as a simple potential car owner, I really appreciated your video made in simple words. Again thank you very much.
Hi, upon further investigation I have determined that you are correct, the labels are reversed. The second generation had two relays on the positive side and one on the negative. The third generation Prius is the opposite with two on the negative and one on the positive. I was also wrong on the contactor verses relay name. Toyota does call them System Main Relays (SMR), I think it is GM and/or Honda that call them contactors. So many different systems, yet all similar. Thanks again!
John is brilliant. I work on these things and wish I could work with him on many of the issues I run into. Amazing WEALTH of knowledge and fantastic explanations. I've learned so much watching his videos and his breakdowns on how these Hybrid Synergy Drive systems work.
Wow, thank you! I already had some basic knowledge of hybrid vehicle technology, but this is the absolute best breakdown video I have ever watched! I now know exponentially more than I would have thought possible, and understand my car and it's operation. Thanks!
Hi, The wiring is correct, that part you call a hall sensor is a current sensor. The sensor is used with the precharge contractor and high wattage resistor to detect a stuck closed contactor. The Toyota service information calls the high voltage relays "Contactors". A contractor is typically used in high voltage high current conditions; relays are typically used in lower voltage lower current conditions. Every hybrid vehicle I have read about and received training on uses "Contactors".
Hi, there is not a way to disconnect the battery while driving. The electric motor generators need some place to send the energy created during deceleration, the battery is the storage for that energy.
Awesome terrific nice thanks for that beautiful information i appreciate your time you spend teaching us so important information God bless you and your family have a beautiful day!! Thanks
Hi, No, the high voltage system is totally isolated from the 12V system. It is like a flashlight sitting on your back seat (it has its own isolated power supply).
That's the most comprehensive review I've found, good job. As a Lexus 400h owner, my experience has been mostly with the very small 12V battery. Because the large rear battery will not charge the 12V battery when key is off, you have to be careful not to run that little battery down. I've boosted a few times already and we have booster cables, which are unfortunately hard to get to because the trunk won't open with a drained accessory battery. Boosting is done in the usual way.
Awesome. I teach wind turbine operations and had no idea how similar the Prius electrical system was to the asynchronous generators used on wind turbines.
Please allow me to ask few question , if i may ? What is the maximum charging current inverter converter supply to 12V battery and what happen in case this battery gets short?
Many hybrids have jump start terminals under the hood (even if the battery is in the rear). You might check the owner's manual to see if your model does.
Thank you for such exellent video! Is all hybrid electric connetctors are water insulated in the motor bay? Can it be damaged if some water sprays on it?
@@WeberAuto Thank you for answer. I want to cleand some parts with running water - it's very dirty because of bad winter weather condotion this year. I know, that it's forbidden to wash engine with pressure washer.
This is just great. Thank you very much for this awesome explanatory lesson. I watched this video twice, you are great. Thank you very much. I always thought that there is nothing free in US, i guess i'm wrong. This turned out to be very great free lesson on how hybrid system works. Really appreciate your time and effort on briefly explaining it how this system works. Great stuff.
Thank you John D. Kelly at WSU for confirming my suspicion that the HV wiring labeling is incorrect. At 2:05 the labels should be swapped. The +ve cable being the short one and the -ve cable being the long one.
I came here to say this. If you happen to connect the positive and negative as labeled the resistor is rendered unusable. Took me quite a while to figure out why this happened and how to fix it. I had spent so much time working on the battery itself I had neglected/forgotten exactly how things were connected in the switchbox. I am now running my 2008 with a crudely assembled battery comprised of K2 Energy LFP26650P factory assembled banks, each containing 80(20s4p) cells for a total of 64V and 10.2aH. I have 3.5 of these connected in series and fashioned the leads for the 'modules' to reach the appropriate connecting points. Car is running fine, I think I need to find a way to get each row of 4p cells charged to 60% capacity. The cells are nominally 3.2v LiFePO4 8.32wHr (2.6aHr), so a 'module' is a section of 5s4p for 16V nominal and 10.4aHr vs. factory NimH 14.4V and 6.5aHr. These banks came out of US Navy power system used offshore so they are assembled Stout! I chose to use 'as-is' after attempting to harvest the cells to reconfigure... Lots of sparks, very difficult to get apart... not worth it. The car tries to keep voltage around 230V, the specs of these cells suggests maximum cutoff charging voltage of 3.65v. As power cells they are(were) K2 Energy's version of the LFP26650 to provide more current... I think these were used in what I can best describe as a Pulse Power System? And from other research, perhaps to power weapons systems? These were free, a scrap dealer had them and didn't know what to do with them. Offered them free so I took them not knowing anything about them. I have far more than necessary for my 2 hybrid vehicles, was thinking powerwall utilizing the components I have as close to design as possible. I am getting no help from K2 or Actia who provided the Master BMS 4 for the Master Control Units and the Slave 5 boards 32V. An italian company designed and manufactured the charging module. I have no connectors for any of the components. I've drifted waaaay off topic. @WeberAuto - Excellent Videos!
At 2:18 the two main HV relays are shown labelled Positive and Negative. However, I believe the labeling to be incorrect. The short cable is connected to the +ve post while the long cable is connected to the -ve post. Could you please clarify?
23:32 In theory one could run a cable from the 12V battery to anywhere in the car, add a switch, and return back to connect to the big battery. That way one can have a quick way of disconnecting the 12V battery. Correct?
Thank you Prof.......so amazing to learn how new electric vehicle built, I'm a electric reach truck technician so I can understand what you explain, God bless you even more Sir.....
You mentioned you should not tow the vehicle because it will continue to generate power and could damage the vehicle. How do you get the vehicle to the garage if it will not run? Do you have to put it on a flatbed truck? Is there a way to safely tow it? I have a 2009 Prius that just had the hybrid water pump replaced and it cost me around $420 labor for just 2 hours at Earl Stewart Toyota in North Palm Beach, FL. That is why I'm learning everything I can now about my car so I can fix it myself!
We work on hybrid at our shop, and we use Your illustration to explain to our mechanics, overall (block diagram) system,how to troubleshoot voltages and communications between computers ,Amazing Illustration, Good Job I would like to add a notice that if you decide to tow your vehicle you can use Wheel-lift towing as long front wheels they are not moving (Front wheel drive ),Kindly correct if I am wrong .
Thank you for this quality presentation. I hope you can follow up with more on internal components, things that might fail and what is involved to service them, especially failure mode(s) of the HV battery and reconditioning possibility.
Par contre j'ai une question, si une personne qui se trompe et inverse la polarité des cosses de la batterie 12 V par inattention, qu'est-ce qui se passe ? Quelles sont les éléments qui seront touchés 7:56 ?
Thanks for such a great demonstration...What could be the possible reason for the 12 V battery isn't charging...The battery is new and the hybrid battery is also fine...is it the dc dc converter somehow not working?
Yes, the DC-DC converter could be a problem, a fuse could also do it. See my other video on checking the charging system here: th-cam.com/video/_V9PiOpaxyE/w-d-xo.html
Hi love your videos. I have a 2004 Toyota Prius I have been noticed the batteries on the screen was acting unusual. On the low side then the triangle of death came up. It shows one bar the cooling fan came on lacking power but then it would show full Green bars. For a Second or two. Drop to one bar again. I would clear code but nothing showing get home pull off bat cover all batteries are at 7.4v screen showing one bar start it hold brake and gas cooling fan turns on I check voltage it was over 400v my meter only goes to 400v but the screen on dash only shows 1 bar. What would you say. Would appreciate the help. Thanks
Nice video....why did Toyota choose the current battery tech over lithium chemistry? Also, is it possible to convert this technology to a all electric and replace engine with larger battery pac?
I think it was the fact that -1) Nickel Metal Hydride was WAY CHEAPER than lithium back then, & 2) maximum lifespan discharge range is better in nickel vs lithium -2.5 --3.6 volt lithium =60-85% 4.2 volt max -prius nickel pack 40-80%
You amazing teacher man thank you for you time and sharing this absolute valuable information I have Prius 2006 and I don’t know what to do shows on scanner poa94 code. Dc/dc converter performance What can i do man. Please thank you
I think GM uses 6 phase motors generators in the hybrid trucks. I want to go online to learn about ev systems! Im missing my inverter relay and think thats why my high voltage battery only change with wheel motors or i just bought the car a week ago and the blue bars only 6 out of 8 will ever light up. Once all 8 green bars showed charged from the wheels going down a hill. Can some one correct me if im wrong but the blue relay im missing labeled inverter in hood that is important or not supposed to be missing right?
Do you have another video on common failure modes? And what component in the system actually fails? The one I am interested in is when improperly jumping the car and that Aux battery experiences a reverse polarity.
Excellent system view. I am working on my friends 2010 highlander hybrid - the inverter has failed, my expectation was/is the IPM - can the IGBT transistors be compared in circuit amongs all the channels to find out if they are all good, or one/some have failed? In watching your video I’m thinking that possibly the boost inverter or the A/C inverter has failed - we can move the car around using a 12v boost battery hence the primary IPM is not disabled by what ever the failure is - and there are no visible signs of over heating in what we can see. Plan is to replace with a used assembly but I am curious and challenge to find a fault and repair - I’m in the electronics business, but Mech Eng by schooling Your information and courses are great for the future generation mechanics so that knowledge is real and people understand the transition to these technologies instead of fearing and berating it!
I like some here have a problem with a code P3030, checked everything and everything is working great, except for that code, I went ahead and replaced the ECU and once everything was done I got the code P0AFA now!! I double checked voltage on each cell, checked the wiring harness and nothing, I just can’t get rid of these two codes ( one on each ECU) any suggestions about what else could I check? I’ll appreciate any sugestión
0:00 I remember in one of your newest videos you talk about that red high voltage glove thats hanging on the wall. Its crazy how much it deteriorated over 7 years.
Excellent learning material.... I have watched your video many times despite the camera movement..I have learned a lot about hybrid electrical system...If you can only improve your video by using a tripod on your camera with an assistant to focus the camera on your visual materials, I'm sure , this will make WSU a big HIT on youtube like a blockbuster.. More power and million thanks.
Extremely interesting and technically-oriented. Seeing the cut-aways and the cabling in real life sizes takes some of the mystery out of it. Thanks for showing us your setup. Students at your school should be able to learn about the Hybrid system very easily. BTW, you mentioned about never towing a hybrid vehicle. What does someone do if they need a tow? Call a flat bed truck?
If you have to tow lift the front wheels off the ground only if it's a front wheel drive vehicle. If it's an all wheel drive like some the RX and Highlanders you will need that flat bed
Weber State University thank you so much. i need some help with my prius. I do not have electrical current in the a/c compressor and I would like to know what elements I should look for
Hello i have got a prius in my workshop where it says ready and makes alot of clicking clacking noises and the wheels do move for 3 seconds on and off on the vehicle lift and then it stops, i have tested mg1 and mg2 resistance to bidy earth and its between 5-6 m-ohm, which part of the inverter do i need to test and do you have the reference readings please? Fault code is P0A7A generator inverter performance, fantastic video sir
I have had that thought myself. There are three concerns. 1. Battery cooling. 2. Inverter converter cooling. 3. Battery monitoring. I couldn't figure out a way to make it work.
Thanks a lot for the explanations. Do you think it is possible to use this battery as a stand along power backup module to be connected to high voltage UPS (192V DC 4 kva invertor which operates battery in the range of cut-off 158 VDC to 220VDC) Charge 220 VDC 8A
Just an off the wall question, but is there any way to tap into the 3 phase output in the inverter/converter and use it for my welding? I think this would work great in field applications on an older model prius. Could I use the battery as a power bank for my solar panels on my home if I tap into the 200 volt battery?
Fantastic overview….Question Sir if I may. How is charge current captured from MG2 during regen braking? I understand that MG2 transitions into gen mode but how if the inverter is dropping the applied frequency to the stator coils to control deceleration rate? Does it rapidly toggle between slowing motor and “collecting” the induced current from the slowing PM rotor? Any clarification would be greatly appreciated?
@@WeberAuto this needs to be mentioned in this video or put in the comment section below the video. very important that people know that the output wires are mislabeled.
Yes, because they are in series with each other. This is similar to the older Christmas tree lights; when one went out, they all went out. Best wishes.
hello I have problems with my Toyota Prius 2007 it has the code p0a78 that talks about low voltage of the inverter .. the inverter has already been replaced and it still has the same code. the car has a red corner and cannot be driven. any advice ?
Greetings sir.. i have a major problem with my toyota prius C HV battery... all i did was to clean up the buss bars and put it all back together but when i connect the service plug grip it ignites and burn out the whole connection... is this a common problem?
I have a question on the high power cable that runs from the hybrid battery to the inverter. Can a faulty high power cable cause fumes from bad insulation to go inside the cabin? I’m getting a electrical smell/taste in my mouth when I drive my PRIUS. Is there a way to test for a faulty high voltage cable?
Not likely a cable problem, the cables run under the vehicle. Check your 12V battery. Make sure it is an AGM battery with a vent tube that vents through the floor through a rubber tube. The high voltage battery also has a vent that vents through the floor.
WeberAuto I have a 2012 Toyota Prius and people that do battery reconditioning and replacement have told me that they did away with traction battery venting in the newer PRIUS that includes mine.
Very informative video. Have wondered about all of this for some time. Many thanks for your generosity. What an amazing vehicle. Mine is a 2007 model with 252,000km on the clock. All the best.
This gentleman is a world class teacher. I don't have a Prius, but after stumbling apon this video I just had to subscribe.
The way the information is relayed to the viewing audience is as high a quality as the engineering in question. Respect.
You encouraged me to work on inverter/converter unit on my 2007 Prius. Dealership wanted to charge me 5k for it but it cost me $300 on used unit. My Prius is almost 277, 000 miles and counting!!!! Thank you so much.
Awesome, good job!
Was it hard do it ,my 2012 Prius converter with bad at 122,000 miles . It still had warranty I save $4200. I got 4 years more of warranty or 30,000 miles more until warranty ends lol
Good Morning!
I am a Brazilian automotive specialist graduated from SENAI and General Motors Brasil!
Weber, congratulations, excellent technical video!
May God bless you and keep making other videos with this technical ability!
Grateful
Wilmar Ribeiro
You are absolutely brilliant, wonderful and very intelligent and calm person sir. This is absolutely free knowldge you are providing us. I am very grateful to you. I wish that i could be in your class to learn from you. I thank you so much for making all these videos.
Thank you!
I do not know English very well, but I've seen many videos of you. You are an excellent and extremely professional teacher. For 3 or 4 years I subscribed to your channel and I liked all the videos I've seen. I work the electronics of the cars. I know something about robotics, mechanics, electronics. I think cars are robot with wheels. I like the electrics and I think the hybrids are a step to them and until the infra-structure is created so that we can all have an electric car, the hybrids are good. I had a 2006 Honda Civic Hibrid. I bought it in 250 dollars because they were going to join it. In a few hours I put it to work. Now I have a 2006 Toyota Prius. It does not work With what little I've seen, I've learned that it's very different from Honda. It has helped me a lot to see all your videos of the Toyotas II Generation. The high voltage batteries had 190 volts. They had a lot of sulfate in the contacts. I cleaned everything very well and now it has 201 volts. The scanner gives me two codes: 1) on the HV and it tells me to replace the Inverter-converter module. 2) Replace the battery. When I try to start the relay of the battery block sounds and in the dash it flashes READY 2 or 3 times and then the red triangle appears. I have another module inverter converter equal, but my question is whether it is the module or the batteries. I measure the voltage of them at the moment of starting and lowering something, but in a few seconds they return to 201 volts. I also want to know if the starter of this car is only for the MG1 or has an external one. I already learned with you that it has no alternator, which it does through the conversion of 201.6 to 12 in the inverter module of the A / C. I know that the Honda does have a starter, but it still does not. Please, I need your help. You can answer me in English and I use the google translator, but if you can send me some documentation in Spanish I would also appreciate it. Thank you very much for all your videos. I'm sure you help thousands of people around the world, because you do it with professionalism and love of what you do. Greetings from Tampa, Florida.
Thank you, There is no starter, MG1 starts the engine. It sounds like you still have a battery problem. The converter trouble code is not a good sign either. Best wishes
This teaching setup is incredible! Thank you so much for taking the time to share this information us. The prius is such an incredible vehicle and this layout showcases the components so well!
Glad it was helpful!
Приус это шедевр! Высокий импульс творческой мысли, смелое шерение , чудесное поплощение!!! Быть добру!!! Таёта I LOVE YOU!
Excellent Video!! Thank You!. at 17:30 to 18:00 Min, how much current is the DC to DC 12 volt battery supply capable of producing at 12-14.5 Volts? I want to hook up a 120 Volt power inverter to the 12 volt battery in the back.
100 amps, but the car uses up to 78 amps with the engine running. Not much left for an inverter. The 12V battery will make up the rest as it slowly goes dead. See th-cam.com/video/_V9PiOpaxyE/w-d-xo.html
Thanks John! I'm thinking to buy an used 2nd gen Prius and with no knowledge on the area, as a simple potential car owner, I really appreciated your video made in simple words. Again thank you very much.
Thank you! Best wishes
Hi, upon further investigation I have determined that you are correct, the labels are reversed. The second generation had two relays on the positive side and one on the negative. The third generation Prius is the opposite with two on the negative and one on the positive. I was also wrong on the contactor verses relay name. Toyota does call them System Main Relays (SMR), I think it is GM and/or Honda that call them contactors. So many different systems, yet all similar. Thanks again!
John is brilliant. I work on these things and wish I could work with him on many of the issues I run into. Amazing WEALTH of knowledge and fantastic explanations. I've learned so much watching his videos and his breakdowns on how these Hybrid Synergy Drive systems work.
Danke für Ihre Arbeit, Herr Kelly. Sie sind ein fantastischer Lehrer. Thx for your work, Mr. Kelly. You are a fantastic teacher.
this guy deserves money
+Wayne D Thank you!
WAYNE D ad revenue ;)
This genteleman is possible an Assistant Professor or a Professor with either an MS or possibly a Phd.
Wow, thank you! I already had some basic knowledge of hybrid vehicle technology, but this is the absolute best breakdown video I have ever watched! I now know exponentially more than I would have thought possible, and understand my car and it's operation. Thanks!
Thank you!
This is well above my head and I will need to watch this couple of times. Very well presented and useful information!
Hi, The wiring is correct, that part you call a hall sensor is a current sensor. The sensor is used with the precharge contractor and high wattage resistor to detect a stuck closed contactor. The Toyota service information calls the high voltage relays "Contactors". A contractor is typically used in high voltage high current conditions; relays are typically used in lower voltage lower current conditions. Every hybrid vehicle I have read about and received training on uses "Contactors".
Hi, there is not a way to disconnect the battery while driving. The electric motor generators need some place to send the energy created during deceleration, the battery is the storage for that energy.
Awesome terrific nice thanks for that beautiful information i appreciate your time you spend teaching us so important information God bless you and your family have a beautiful day!! Thanks
Hi, No, the high voltage system is totally isolated from the 12V system. It is like a flashlight sitting on your back seat (it has its own isolated power supply).
That's the most comprehensive review I've found, good job. As a Lexus 400h owner, my experience has been mostly with the very small 12V battery. Because the large rear battery will not charge the 12V battery when key is off, you have to be careful not to run that little battery down. I've boosted a few times already and we have booster cables, which are unfortunately hard to get to because the trunk won't open with a drained accessory battery. Boosting is done in the usual way.
Excellent presentation and amazing engineering by Toyota. I just bought the 2008 Prius and wanted to learn more about the system.
Awesome. I teach wind turbine operations and had no idea how similar the Prius electrical system was to the asynchronous generators used on wind turbines.
Yes, very similar! Thanks for your feedback!
Please allow me to ask few question , if i may ? What is the maximum charging current inverter converter supply to 12V battery and what happen in case this battery gets short?
John, that clock says 11:25. It's either time for lunch or time for bed. Great video.
Many hybrids have jump start terminals under the hood (even if the battery is in the rear). You might check the owner's manual to see if your model does.
great demonstration..Could you have the isolation relays wrongly labled.the arc aresting component on mine is across the positive isolation relay.
Simply the best video, no comparison. This is truly professional.
Thank you for such exellent video!
Is all hybrid electric connetctors are water insulated in the motor bay? Can it be damaged if some water sprays on it?
Yes, they are made to have water splashed on them. They are not made to keep out high pressure water from a pressure washer.
@@WeberAuto Thank you for answer. I want to cleand some parts with running water - it's very dirty because of bad winter weather condotion this year. I know, that it's forbidden to wash engine with pressure washer.
This is just great.
Thank you very much for this awesome explanatory lesson.
I watched this video twice, you are great.
Thank you very much.
I always thought that there is nothing free in US, i guess i'm wrong. This turned out to be very great free lesson on how hybrid system works.
Really appreciate your time and effort on briefly explaining it how this system works.
Great stuff.
Thank you John D. Kelly at WSU for confirming my suspicion that the HV wiring labeling is incorrect. At 2:05 the labels should be swapped. The +ve cable being the short one and the -ve cable being the long one.
Thanks for catching my error. have a good day
I came here to say this. If you happen to connect the positive and negative as labeled the resistor is rendered unusable. Took me quite a while to figure out why this happened and how to fix it. I had spent so much time working on the battery itself I had neglected/forgotten exactly how things were connected in the switchbox. I am now running my 2008 with a crudely assembled battery comprised of K2 Energy LFP26650P factory assembled banks, each containing 80(20s4p) cells for a total of 64V and 10.2aH. I have 3.5 of these connected in series and fashioned the leads for the 'modules' to reach the appropriate connecting points. Car is running fine, I think I need to find a way to get each row of 4p cells charged to 60% capacity. The cells are nominally 3.2v LiFePO4 8.32wHr (2.6aHr), so a 'module' is a section of 5s4p for 16V nominal and 10.4aHr vs. factory NimH 14.4V and 6.5aHr. These banks came out of US Navy power system used offshore so they are assembled Stout! I chose to use 'as-is' after attempting to harvest the cells to reconfigure... Lots of sparks, very difficult to get apart... not worth it. The car tries to keep voltage around 230V, the specs of these cells suggests maximum cutoff charging voltage of 3.65v. As power cells they are(were) K2 Energy's version of the LFP26650 to provide more current... I think these were used in what I can best describe as a Pulse Power System? And from other research, perhaps to power weapons systems? These were free, a scrap dealer had them and didn't know what to do with them. Offered them free so I took them not knowing anything about them. I have far more than necessary for my 2 hybrid vehicles, was thinking powerwall utilizing the components I have as close to design as possible. I am getting no help from K2 or Actia who provided the Master BMS 4 for the Master Control Units and the Slave 5 boards 32V. An italian company designed and manufactured the charging module. I have no connectors for any of the components. I've drifted waaaay off topic. @WeberAuto - Excellent Videos!
10:37 does capacitor and inverter make whining noise which is audible while driving? is it normal?
Hi Professor, I'm hopping you could answer my question. Is it possible to run three phase power from the inverter to power up one's house ?
I do not know
@@WeberAuto Thank you for sharing your knowledge.
Fantastic job my friend. Learned a lot on that electrical system. Gives me a way better understanding on how the car works
At 2:18 the two main HV relays are shown labelled Positive and Negative. However, I believe the labeling to be incorrect. The short cable is connected to the +ve post while the long cable is connected to the -ve post.
Could you please clarify?
I labeled them incorrectly, they should be switched
Bonjour, je suis très ravie de la vidéo , je vous remercie car vos explications sont très claires , je continue à vous suivre.
absolutely concise. loved it.
15 nuff nuffs showed their stupidity by thumbs downing this material. WHAAAAT?
+Gods Phone Thank you!
23:32 In theory one could run a cable from the 12V battery to anywhere in the car, add a switch, and return back to connect to the big battery. That way one can have a quick way of disconnecting the 12V battery. Correct?
The prius 2018 what volt the a/c compressor? Thanks 16:41
Thank you Prof.......so amazing to learn how new electric vehicle built, I'm a electric reach truck technician so I can understand what you explain, God bless you even more Sir.....
Thank you sir, this is what I was looking for.
You mentioned you should not tow the vehicle because it will continue to generate power and could damage the vehicle. How do you get the vehicle to the garage if it will not run? Do you have to put it on a flatbed truck? Is there a way to safely tow it? I have a 2009 Prius that just had the hybrid water pump replaced and it cost me around $420 labor for just 2 hours at Earl Stewart Toyota in North Palm Beach, FL. That is why I'm learning everything I can now about my car so I can fix it myself!
Amazing! So well explained. Thank You Professor. It is a marvelous travel trough my favorite vehicle.
Thank you very much
We work on hybrid at our shop, and we use Your illustration to explain to our mechanics, overall (block diagram) system,how to troubleshoot voltages and communications between computers ,Amazing Illustration, Good Job
I would like to add a notice that if you decide to tow your vehicle you can use Wheel-lift towing as long front wheels they are not moving (Front wheel drive ),Kindly correct if I am wrong .
Thank you! Yes, you are correct, front wheels must be off the ground.
Thank you for this quality presentation. I hope you can follow up with more on internal components, things that might fail and what is involved to service them, especially failure mode(s) of the HV battery and reconditioning possibility.
Outstanding demonstration for this HV. WSU Automotive Technology 'Great job'.
Par contre j'ai une question, si une personne qui se trompe et inverse la polarité des cosses de la batterie 12 V par inattention, qu'est-ce qui se passe ?
Quelles sont les éléments qui seront touchés 7:56 ?
Many thanks indeed for this awesome video... 👌
Better than the wikipedia article, love it
Only thing i cant find out anywhere is a power rating of the ac compressor
Thank you! I do not know what the power rating is either.
Thanks for such a great demonstration...What could be the possible reason for the 12 V battery isn't charging...The battery is new and the hybrid battery is also fine...is it the dc dc converter somehow not working?
Yes, the DC-DC converter could be a problem, a fuse could also do it. See my other video on checking the charging system here: th-cam.com/video/_V9PiOpaxyE/w-d-xo.html
Great effort. Thank you very much
Is this like standard 3 phase that needs a star delta start circuit?
Hi , were should we contact a V2H 3 phase output to run the house , using the car az an agregator?
excellent is there a video for the plug in version?
thank you for detailed explanation of the toyota system . . . so very completely well understood . . .
Thank you!
Hi love your videos. I have a 2004 Toyota Prius I have been noticed the batteries on the screen was acting unusual. On the low side then the triangle of death came up. It shows one bar the cooling fan came on lacking power but then it would show full Green bars. For a Second or two. Drop to one bar again. I would clear code but nothing showing get home pull off bat cover all batteries are at 7.4v screen showing one bar start it hold brake and gas cooling fan turns on I check voltage it was over 400v my meter only goes to 400v but the screen on dash only shows 1 bar. What would you say. Would appreciate the help.
Thanks
Nice video....why did Toyota choose the current battery tech over lithium chemistry? Also, is it possible to convert this technology to a all electric and replace engine with larger battery pac?
Thank you. Toyota was worried about keeping the batteries cool. The 4th generation Prius uses Li-ion batteries
I think it was the fact that
-1) Nickel Metal Hydride was WAY CHEAPER than lithium back then, &
2) maximum lifespan discharge range is better in nickel vs lithium
-2.5 --3.6 volt lithium =60-85%
4.2 volt max
-prius nickel pack 40-80%
Mr. Weber
What would you recommend disconnecting if one were to perform flux/arc welding on this Prius other than the 12volt auxiliary battery +/- ?
You amazing teacher man thank you for you time and sharing this absolute valuable information I have Prius 2006 and I don’t know what to do shows on scanner poa94 code. Dc/dc converter performance What can i do man. Please thank you
Absolutely an awesome video. Thank you very much for this.
Congratulation for the helpful explanation. It´s good to learn from another Professor.
So can you charge your hybrid battery by towing your Prius with another vehicle
Great video!!! When replacing the transmission let's say, Is " removing the service plug grip" good enough to work under the hood? Thanks.
How does the engine work i mean i thouthgt it could go with out main battery
Excellent video. Very informative.
I think GM uses 6 phase motors generators in the hybrid trucks. I want to go online to learn about ev systems! Im missing my inverter relay and think thats why my high voltage battery only change with wheel motors or i just bought the car a week ago and the blue bars only 6 out of 8 will ever light up. Once all 8 green bars showed charged from the wheels going down a hill. Can some one correct me if im wrong but the blue relay im missing labeled inverter in hood that is important or not supposed to be missing right?
Do you have another video on common failure modes? And what component in the system actually fails? The one I am interested in is when improperly jumping the car and that Aux battery experiences a reverse polarity.
Does the Negative side of the high voltage system connect to chassis ground at any point like the 12v system?
Excellent system view.
I am working on my friends 2010 highlander hybrid - the inverter has failed, my expectation was/is the IPM - can the IGBT transistors be compared in circuit amongs all the channels to find out if they are all good, or one/some have failed?
In watching your video I’m thinking that possibly the boost inverter or the A/C inverter has failed - we can move the car around using a 12v boost battery hence the primary IPM is not disabled by what ever the failure is - and there are no visible signs of over heating in what we can see.
Plan is to replace with a used assembly but I am curious and challenge to find a fault and repair - I’m in the electronics business, but Mech Eng by schooling
Your information and courses are great for the future generation mechanics so that knowledge is real and people understand the transition to these technologies instead of fearing and berating it!
@JrgrimWoW Hi, thank you. I must have forgotten to mention the "Flux Capacitor" and the "Jiga-Watts" of power. :)
I like some here have a problem with a code P3030, checked everything and everything is working great, except for that code, I went ahead and replaced the ECU and once everything was done I got the code P0AFA now!! I double checked voltage on each cell, checked the wiring harness and nothing, I just can’t get rid of these two codes ( one on each ECU) any suggestions about what else could I check? I’ll appreciate any sugestión
Possible corrosion and poor connections between battery modules. See th-cam.com/video/utDVUNUC474/w-d-xo.html
This was very informative, I really need full knowledge of all components and buttons in the jump start box!!
0:00 I remember in one of your newest videos you talk about that red high voltage glove thats hanging on the wall. Its crazy how much it deteriorated over 7 years.
Excellent learning material.... I have watched your video many times despite the camera movement..I have learned a lot about hybrid electrical system...If you can only improve your video by using a tripod on your camera with an assistant to focus the camera on your visual materials, I'm sure , this will make WSU a big HIT on youtube like a blockbuster.. More power and million thanks.
+art rigor Hi, Thanks for the feedback and thanks for the compliments!
ThanK you so much... You're amazing and your explanations are quite unique and understandable... Thanks a bunch
Thank you
Excellent presentation. Thank you.
Truly appreciated! Is there any high-voltage fuse protection for the Gen2 A/C compressor circuit?
Good question! I do not know of one. Best wishes.
Hi Prof, as usual great video. Just wanted to check if there are no refrigerant in the air con pump will it throw a code? POAA6?
Thank you. Lack of refrigerant will not cause that DTC; however, the wrong refrigerant oil will cause that DTC. Best wishes
Outstanding John. Thank you.
Thank you!
Can you run 2002 prius with engine only gut hybrid system
Amazing layout wonderful knowledge simple straight to the point all amazing matainance tips and reminders
I am living in Austin Texas, which school is better for Hybrid cars?
I can’t help you there. Sorry
The one before your eyes.
it looks to me the neg. and pos. are the wrong way around labeled
the neg goes with the hall effect sensor
also these are relays and not contactors
the code machine said bank 1 p3011 which side is this toword the computer or ?
Extremely interesting and technically-oriented. Seeing the cut-aways and the cabling in real life sizes takes some of the mystery out of it. Thanks for showing us your setup. Students at your school should be able to learn about the Hybrid system very easily. BTW, you mentioned about never towing a hybrid vehicle. What does someone do if they need a tow? Call a flat bed truck?
Thanks for the feedback! Yes, call a flat bed tow truck.
why?
+Marcos Robles: Watch the video for the answer, it's at 21:50
If you have to tow lift the front wheels off the ground only if it's a front wheel drive vehicle. If it's an all wheel drive like some the RX and Highlanders you will need that flat bed
Greetings, very good video, I would like to know where the Hybrid battery temperature sensor A circuit high is located
Weber State University thank you so much.
i need some help with my prius. I do not have electrical current in the a/c compressor and I would like to know what elements I should look for
Hello i have got a prius in my workshop where it says ready and makes alot of clicking clacking noises and the wheels do move for 3 seconds on and off on the vehicle lift and then it stops, i have tested mg1 and mg2 resistance to bidy earth and its between 5-6 m-ohm, which part of the inverter do i need to test and do you have the reference readings please? Fault code is P0A7A generator inverter performance, fantastic video sir
Thank you. The resistance should be much higher (500 Mega-ohm)
Hi, I have an extra HV battery. What would happen if I connect both HV batteries in parallel prior to the relays? Thank you.
I have had that thought myself. There are three concerns. 1. Battery cooling. 2. Inverter converter cooling. 3. Battery monitoring. I couldn't figure out a way to make it work.
Very helpful sir but . engine does not crank no codes assuming there's no starter where to test or how test ?? Thanks
Always check for trouble codes and follow their diagnostics.
No trouble codes
@@luiguimartinez820 Make sure your 12V battery is good and start checking fuses, and electrical connectors for looseness or damage.
@@WeberAuto thanks😁😁
hi great video, thank you.. how much the ac voltage level for MG1 and MG2 during operating for motoring and generating?
Thanks a lot for the explanations.
Do you think it is possible to use this battery as a stand along power backup module to be connected to high voltage UPS (192V DC 4 kva invertor which operates battery in the range of cut-off 158 VDC to 220VDC) Charge 220 VDC 8A
Thanks for watching. Probably, but this battery only has a 5 Ah rating.
Just an off the wall question, but is there any way to tap into the 3 phase output in the inverter/converter and use it for my welding? I think this would work great in field applications on an older model prius. Could I use the battery as a power bank for my solar panels on my home if I tap into the 200 volt battery?
Fantastic overview….Question Sir if I may. How is charge current captured from MG2 during regen braking? I understand that MG2 transitions into gen mode but how if the inverter is dropping the applied frequency to the stator coils to control deceleration rate? Does it rapidly toggle between slowing motor and “collecting” the induced current from the slowing PM rotor? Any clarification would be greatly appreciated?
No, is is only creating an opposing voltage to counteract the induced voltage produced while decelerating. Thanks for watching
@@WeberAuto Thank you Sir. Having great difficulty in finding details.
The negative and positive contactors are mislabeled...
The pre-charge capacitor & 20 ohm resistor are on the positive HV contactor...
Thanks for your feedback!
@@WeberAuto this needs to be mentioned in this video or put in the comment section below the video. very important that people know that the output wires are mislabeled.
Shut up, you pointed it out and he acknowledged it, now take a hike
So cool! What a great teacher. Wish I could be a student here!
Thank you!
Hello again, Is it true that if one battery cell voltage drops (goes bad) affect the entire HV battery? Why!?
Yes, because they are in series with each other. This is similar to the older Christmas tree lights; when one went out, they all went out. Best wishes.
hello I have problems with my Toyota Prius 2007 it has the code p0a78 that talks about low voltage of the inverter .. the inverter has already been replaced and it still has the same code. the car has a red corner and cannot be driven. any advice ?
Greetings sir.. i have a major problem with my toyota prius C HV battery... all i did was to clean up the buss bars and put it all back together but when i connect the service plug grip it ignites and burn out the whole connection... is this a common problem?
I have a question on the high power cable that runs from the hybrid battery to the inverter. Can a faulty high power cable cause fumes from bad insulation to go inside the cabin? I’m getting a electrical smell/taste in my mouth when I drive my PRIUS. Is there a way to test for a faulty high voltage cable?
Not likely a cable problem, the cables run under the vehicle. Check your 12V battery. Make sure it is an AGM battery with a vent tube that vents through the floor through a rubber tube. The high voltage battery also has a vent that vents through the floor.
WeberAuto I have a 2012 Toyota Prius and people that do battery reconditioning and replacement have told me that they did away with traction battery venting in the newer PRIUS that includes mine.
That is not true, they all have venting. The 2016 Prius has the battery under the hood now, but it still has vents. (not through a tube though)
Very informative video. Have wondered about all of this for some time. Many thanks for your generosity. What an amazing vehicle. Mine is a 2007 model with 252,000km on the clock. All the best.
Thank you!