EV Powers – Hymotion L5 User Guide V03
Contents
1. for four to five seconds This indicates a proper connection During the charge cycle the tail lights remain dimly lit and go entirely dim when the L5 PCM is fully charged as shown in Figure 6 The LS PCM can be charged at any time regardless of its State of Charge SOC Ittakes approximately 5 5 hours to charge a fully depleted LS PCM e The LS PCM is only charged from an electrical outlet It will not receive any regenerative charge during the drive cycle Tail lights on when LS PCM is charging Figure 6 Charging indicators NOTE WARNING To prevent the user from driving off while the vehicle is charging the 1 5 PCM activates an interlock feature that disables the vehicle s POWER button Disconnect the extension cord if the vehicle must be moved during the charge cycle The electrical outlet used for charging the LS PCM must be rated for 15 and must be equipped with GFCI Do not use an extension cord that shows any evidence of damage If the cord becomes warm during charging use a heavier gauge cord Periodically check the cord for cuts abrasions or loose connections Do NOT leave the cord in standing water or drive over it Failure to use a properly rated cord or use of a damaged cord could result in serious injury or death Page 15 L5 Removal A WARNING Page 16 At the end of its service life the LS PCM can be removed from your vehicle by an authorized Green CHIP dealer For2. gt SLLJITIDE IODS L5 Plug In Conversion Module PCM Owner s Manual Model LS PCM 123 Inc 508 497 7398 Release 03 www a123systems com 401144 001 SYSTEMS wwwhymotion com Copyright 2008 A123Systems Inc All rights reserved Contents Important Safeguards sscscsesssseessneesseecsnecssseecsneccssnecssneesnnessnneesnnecsneeenneennents 1 Introducing the Hymotion L5 Plug In Conversion Module 6 Operating 10 Troubleshooting LSPEN 17 Support and Sovita 20 Tips to Improve your Fuel ECOMOMY 21 EPMA SE 22 5 Recycled amp Important Safeguards WARNING WARNING The following safety precautions must be observed when using rechargeable batteries READ ALL INSTRUCTIONS IN THIS OWNER S MANUAL BEFORE USING YOUR HYMOTION LS PCM LITHIUM ION BATTERY MUST BE RECYCLED OR DISPOSED OF PROPERLY Read all warnings carefully to reduce the risk of fire electric shock or injury Recycling the LS PCM When the LS PCM requires disposal please contact an authorized Green CHIP dealer The LS PCM must only be removed and disposed of through a Green CHIP dealer who will forward the LS PCM to a professional battery recycler for proper recycling and disposal Removal of the LS P
3. labor for the repair which would have otherwise been covered by the Toyota Express Warranty provided however that prior to initiating the repair services you receive pre authorization from A123 for any repair A123 shall not be responsible for any parts and labor costs which a did not receive the required pre authorization or b arise from a Toyota Express Warranty that is voided for reasons other than those set forth above To receive warranty service for your Prius you must present your vehicle to any authorized Toyota dealer in accordance with the terms of the Prius warranty Should you require pre authorization approval from A123 for Prius warranty service please contact A123 Hymotion Customer Service Page 23 24 A123Systems only responsibility under this warranty is to reimburse you or our Green CHIP Dealer provided such Green CHIP Dealer is an authorized Toyota dealer for the actual cost of the parts and labor for the repair which would have otherwise been covered by the Toyota Express Warranty provided however that under no circumstances shall A123 s cumulative liability under this warranty exceed the then current replacement cost of the vehicle calculated in accordance with the then current Blue Book value of the vehicle at the time of the repair request 3 General Provisions The following provisions apply to the limited warranties set forth in section 1 and 2 above This warranty applies only to your Product instal
4. missing or altered 6 the Product has been damaged by or the claim results from accident misuse improper charging neglect or improper service c the Product has been modified or used in a manner contrary to its intended purpose or as provided in the user manual or d the Product has been opened by any unauthorized person including the purchaser This warranty does not cover damages that result from abuse accidents or fire flood or other acts of God Removal installation transportation labor inconvenience damage or other components personal damage or injury and or any injury or liability to other persons or property are specifically excluded from this limited warranty 2 Interaction With Prius Factory Limited Parts and Labor Warranty A123 warrants that if as a direct or indirect result of the Product Toyota Motor Sales USA Inc Toyota voids warranty claim on your Prius under their express warranty Toyota Express Warranty which but for the demonstrable installation of Product by A123 ora Green CHIP Dealer and the interaction of the Product with your Prius would not have resulted in the warranty claim A123 atits sole option shall either a reimburse you for the actual cost of the parts and labor for the repair which would have otherwise been covered by the Toyota Express Warranty or 2 reimburse our Green CHIP Dealer provided such Green CHIP Dealer is also an authorized Toyota dealer for the actual cost of the parts and
5. returned to its original state at the time of purchase at no additional cost to you The remedies set forth in this paragraph are your sole and exclusive remedy in the event of a voluntary recall In the event you choose not to participate in a voluntary recall to the extent permitted by law the express warranties set forth in Section 1 and 2 above shall be void EXCEPT AS EXPRESSLY SET FORTH ABOVE NO OTHER WARRANTIES ARE EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND A123 EXPRESSLY DISCLAIMS ALL WARRANTIES NOT EXPRESSLY STATED HEREIN THE DURATION OF ANY IMPLIED WARRANTY INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE LIMITED TO THE DURATION OF THE APPLICABLE EXPRESS WARRANTY SET FORTH ABOVE IN THE EVENT THAT A PRODUCT PROVES TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP WITHIN THE WARRANTY PERIOD YOUR SOLE AND EXCLUSIVE REMEDY SHALL BE REPAIR OR REPLACE MENT AS PROVIDED HEREIN IN NO EVENT SHALL A123 SYSTEMS BE LIABLE FOR ANY LOSS OR DAMAGES WHETHER DIRECT INCIDENTIAL CONSEQUENTIAL OR OTHERWISE RESULTING FROM A BREACH OF ANY EXPRESS OR IMPLIED WARRANTIES OR FROM THE USE OR OPERATION OF THE PRODUCT EXCEPT AS EXPRESSLY SET FORTH HEREIN This warranty gives you specific legal rights and you may also have other rights that vary from state to state Some states do not allow the exclusion or limitation of incidental o
6. the L5 Never remove or disassemble the LS PCM yourself This could result in serious injury or death If you wish to remove the LS PCM you must contact an authorized Green CHIP dealer WARNING WARNING WARNING WARNING Power Switch Do not shut off the LS PCM while driving except in an emergency Shutting off the LS PCM while driving can clear your vehicle s settings such as cruise control and could result in serious injury or death Liquids Take care to avoid spilling liquids in the trunk of your vehicle Do not wash the LS PCM with water or any liquids In the event liquid gets into the LS PCM unit it can cause a fire or malfunction resulting in serious injury or death It may also cause body corrosion of the LS PCM Charge Port If the ground terminal on the bumper charge port has any evidence of corrosion or appears damaged in any way contact an authorized Green CHIP dealer Do not charge the LS PCM until the situation is resolved Charging the 15 PCM when there is evidence of corrosion or damage could result in serious injury or death Extension Cord The LS PCM must be charged using an Underwriters Laboratories UL listed 12 3 American Wire Gauge AWG or 14 3 AWG contractor grade extension cord approved for outdoor use If the cord becomes warm during charging use a heavier gauge cord Do not use a cord that shows any evidence of damage Failure to use a properly rated cord or use of a damaged co
7. CM or failure to dispose of the LS PCM correctly could result in serious injury or death Precautions for using the LS PCM The 15 PCM contains a high voltage electrical system that is dangerous and could result in serious injury or death including severe burns or electric shock To avoid personal injury follow all the caution labels attached to the 15 PCM and do not open the top cover The LS PCM should only be serviced by a Green CHIP dealer Page 1 2 WARNING WARNING WARNING Ifa vehicle accident occurs When involved in a vehicle accident pull your vehicle off the road and shut off the L5 PCM If your vehicle has major damage you may get an electric shock To prevent this never touch the cables connecting the LS PCM to your vehicle or any orange high voltage cable at any time If there are exposed wires do not touch them If fluid leaks from the LS PCM do not touch it If fluid gets into your eyes wash eyes immediately with a large amount of water and seek medical attention If a vehicle fire occurs extinguish it using a fire extinguisher that has been approved for use on electrical fires If your vehicle needs to be towed follow the towing procedures specified by the vehicle manufacturer High Voltage Cables The LS PCM is equipped with high voltage cables connecting it to your vehicle Never touch the cables that connect the LS PCM to your vehicle or any orange high voltage cable at any time Removal of
8. IP dealer 15 hybrid system LS PCM LED status Possible issue with LS PCM Verify that the LED status indicator light indicator lightis continues to blink after two consecutive blinking drives separated by atleast five minutes If this is the case contact your Green CHIP dealer Page 19 Product Support and Service In regular operation the L5 PCM does not require periodic service inspection or maintenance However should product support or service become necessary contact your Green CHIP dealer For Green CHIP contact information go to www hymotion com or call 508 497 7398 Your Prius should be serviced and maintained according to the guidelines recommended in the Prius Owner s Manual The LS PCM does not need to be disconnected or isolated from the vehicle for Prius service to occur A123Systems Hymotion Product Support Call 508 497 7398 Email hymotionsupport a123systems com Hours Monday through Friday 10 am to 6 pm Eastern Time Page 20 Tips to Improve your Fuel Economy Gentle Acceleration Gently accelerating allows the gasoline engine to remain disengaged in many circumstances Use the pulse amp glide technique of acceleration to help disengage the engine To pulse amp glide ease off the accelerator to disengage the engine then gently accelerate to increase vehicle speed using electric power Observe the posted speed limit Using the Prius Display Climate Contro
9. LS PCM removal or recycling bring your vehicle to an authorized Green CHIP dealer Unauthorized removal of the LS PCM from the vehicle will void the LS PCM warranty Consult an authorized Green CHIP dealer for proper disposal of the LS PCM Failure to dispose of the L5 PCM correctly could result in serious injury or death Troubleshooting the L5 PCM The LS PCM system provides you with troubleshooting and resolution procedures These procedures are designed to resolve minor problems without taking your vehicle into your Green CHIP dealer During troubleshooting you may use some of the procedures below Resetting communications between the L5 PCM and Prius Some temporary and minor problems could be resolved by resetting and saving the Prius communication and diagnostic codes This is done by turning the vehicle off and on five times pausing a minimum of thirty seconds between cycles Resetting the 1 5 PCM circuit breaker Acircuit breaker is used to protect the LS PCM and its electronics The circuit breaker is located on the front side of the LS PCM and can be reset by depressing the white red cylinder The location and details of the circuit breaker s operation are shown in Figure 7 Figure LS PCM circuit breaker Page 17 18 WARNING If you encounter a problem with your LS PCM you may be able to resolve it using the procedures below If the problem persists or recurs contact your Green CHIP dealer for in
10. ce the defective Product or component thereof or provide without charge the labor and parts necessary to remedy any such defect A123Systems only responsibility under this warranty is to replace or repair the Product and under no circumstances shall A123 s or its Green CHIP Dealer s cumulative liability under this warranty exceed the price paid by you for the Product except as outlined in Paragraph 2 below Interaction with Prius Factory Limited Parts and Labor Warranty PLEASE REGISTER YOUR PRODUCT THROUGH YOUR GREEN CHIP DEALER AT THE TIME OF INSTALLATION TO OBTAIN WARRANTY SERVICE YOU MUST PRESENT YOUR VEHICLE AND PROOF OF PURCHASE TO A GREEN CHIP DEALER AT THE TIME OF SERVICE DURING THE WARRANTY PERIOD Conditions Limitation and Exclusions If you make a warranty claim to A123Systems A123 or its authorized representative reserves the right to inspect your Product before repairing or replacing your Product directly or through a Green CHIP Dealer If upon inspection of your Product no defect in material or workmanship is found then you may be assessed a labor charge for the diagnostic work A123 or the Green CHIP Dealer in its sole discretion will determine whether your Product has a defect in material or workmanship This warranty does not cover any Product that is installed removed serviced or modified by anyone other than A123 Green CHIP Dealer This warranty is void if the Product s date code or serial number is defaced
11. d result in serious injury or death 2 Electrically assisted driving range fuel economy can vary greatly depending on driving style road conditions outside temperature and other factors Refer to Chapter 6 Tips to Improve your Fuel Economy for more information Page 7 Key Features Operating the Prius with the L5 PCM engaged e Electrically assisted driving range of 30 to 40 miles single charge e Upto 100 mpg or greater city highway combined fuel economy within the 30 to 40 mile electrically assisted driving range e Prius resumes standard operation and fuel economy when the L5 is fully depleted or turned off e Maintains the Prius Super Ultra Low Emissions Vehicle SULEV emissions rating e Upto 2 3rds reduction in emissions e Prius Energy Monitor Display indicates the LS State of Charge SOC Safety e Safety interlock prevents driving the Prius while charging converted Prius meets the United States federal vehicle crash test safety standards e Integrated crash sensor electrically isolates the LS PCM collision Page 8 Product Specifications Energy Approximately SkWh Charging temperature range 20 deg F to 140 deg F Operating temperature range 20 deg F to 140 deg F Charging voltage 120V Maximum charging current 10A Charging time 5 5 hrs 25 deg F Required electrical outlet 15A electrical outlet equ
12. e original load carrying capacity by Figure 1 Vehicle load label Page 5 Introducing the Hymotion L5 Plug In Conversion Module PCM Page 6 The LS PCM is a supplemental lithium ion battery installed in the spare tire well of your Toyota Prius as shown in Figure 2 The LS PCM provides approximately 5 kilowatt hours kWh of onboard electrical storage capacity This additional electrical energy enables the Prius to use pure electric drive more often and for longer distances resulting in fuel efficiency gains and 0 emissions reduction over the standard Prius The LS PCM must be recharged from an electrical outlet or extension cord equipped with GFCI The LS PCM does not receive any regenerative charge during driving When the LS PCM is charged the Prius is capable of achieving fuel economy in excess of 100 miles per gallon mpg and reducing COz emissions by up to 2 3rds over the standard Prius The LS PCM can provide electrical assistance for approximately 30 to 40 miles of driving ona single charge before becoming depleted Once the LS PCM s charge has been depleted the vehicle s operation and fuel economy reverts to that of a regular Prius until the LS PCM is recharged by plugging in Figure 2 L5 PCM location in your vehicle WARNING Installation of the LS PCM in a Toyota Prius requires the permanent removal of the spare tire Do not store the spare tire in the vehicle It could become a projectile an
13. ipped with GFCI Weight 187 pounds WARNING Do not exceed the total load capacity of your vehicle Doing so could unbalance your vehicle damaging the tires deteriorating the steering capability or cause an accident Refer to the Prius Owner s Manual regarding the total load capacity of your vehicle Page 9 Operating Instructions The L5 PCM is designed to work seamlessly with your Prius existing drive control and display systems Operate and maintain your modified Prius as you would a standard Prius Refer to the Prius Owner s Manual for vehicle operation and maintenance instructions Driving with the LS PCM installed does not require any special driving techniques The vehicle should be driven in the same manner as a standard Prius Turning the 1 5 PCM On and Off Page 10 1 Set the dashboard switch to the up position for On or the down position for Off See Figure 3 for the location and details of the LS PCM switch 2 When the LS PCM switch is in the On position and the vehicle is in READY mode the LS PCM automatically comes online if it has sufficient electrical charge 3 When the LS PCM switch is left in the On position the LS PCM automatically shuts off when the vehicle is turned off 4 When the LS PCM is turned off or if it fully discharges while driving the LS automatically disengages and standard Prius operation resumes LED Status Light e 15 is charged a Blinking Possible LS PCM pr
14. isplay and the 1 5 PCM begins communicating with the vehicle the display screen could return to the Energy Monitor screen and disrupt the user s temperature adjustment NOTE The L5 PCM utilizes the Prius Electric Vehicle EV mode by requesting EV operation from the Prius hybrid system controller If EV mode is unavailable due to road or driving conditions the Energy Monitor Display could flash a message beep or both Messages and beeping are a normal part of EV mode operation Charging Requirements WARNING The L5 PCM must be charged from GFCI equipped electrical outlet using a UL listed 12 3 AWG or 14 3 AWG contractor grade extension cord approved for outdoor use See Figure 5 for the charge port location Observe the following extension cord requirements e 3 prong grounded cord e Constructed with 12 3 AWG wire no longer than 50 feet OR e Constructed with 14 3 AWG wire no longer than 25 feet e Must be equipped with GFCI if the electrical outlet is not Figure 5 15 PCM charge port location Do NOT use an extension cord constructed of less than 14 gauge wire or a cord longer than 50 feet to charge your L5 PCM Page 13 Charging the L5 To charge the LS PCM Page 14 i 2 Verify the vehicle is turned off Plug an appropriate extension cord into the vehicle s charge port located on the rear bumper as shown in Figure 5 and into an electrical outlet Watch for the tail lights to illuminate
15. itial product support Should you need to bring your car to a Green CHIP dealer for further diagnosis drive your car with the LS PCM switch placed in the Off position Do not ignore the Prius dashboard indicator warning lights or the LS PCM LED indicator light You should not drive with the LS PCM engaged if a problem persists Contact your Green CHIP dealer if a problem recurs or persists PROBLEM POSSIBLE REASON POSSIBLE SOLUTION Vehicle will notstart 1 L5PCMispluggedin and charging 1 Unplug the charging cord This engages the safety interlock 2 Recharge the Prius 12V battery Prius 12V battery has low voltage Improper charging connection 1 Ensure proper connection has been LS PCM circuit breaker is tripped made Watch for the flash of tail lights to indicate a proper connection Reset the LS PCM circuit breaker Check outlet for proper operation 4 Reset the GFCI LS PCM is not charging Problem with the electrical outlet GFCI is tripped oN PROBLEM POSSIBLE REASON POSSIBLE SOLUTION Prius warning lights on Communications errorbetweenLS 1 Reset communications between LS the dashboard are lit PCM and the Prius PCM and Prius 2 Prius 12V battery has low voltage 2 Recharge the Prius 12V battery Contact your Green CHIP dealer if the problem recurs or persists Prius check engine light Possible issue with gasoline engine or Contact your Green CH
16. l When the LS is charged the Prius display indicates the state of charge of the L5 as well as how the LS and gasoline engine are being used for driving The display indicates when the gasoline engine is engaged Use this feedback and apply the pulse amp glide technique to disengage the engine if possible to help minimize use of the gasoline engine The gasoline engine is the only source of heat for your vehicle Use the heater as little as possible to minimize the use of the gasoline engine Using the cooling system on the highway rather than opening the windows increases aerodynamic efficiency The defroster control on the steering wheel always engages the gasoline engine Use the control on the console display to avoid using the gasoline engine Plug in the LS PCM as often as possible to maximize the electrical energy that is available to drive your Prius Keep your tires inflated to the proper Pounds per Square Inch PSI Page 21 Limited Warranty Page 22 1 A123Systems Hymotion L5 Plug in Conversion Module Limited Parts and Labor Product Warranty A123Systems Inc 123 warrants that if the L5 Plug in Conversion Module Product installed in your vehicle proves to be defective in material or workmanship within three 3 years from the date of installation Warranty Period by A123 or an A123 Certified Hymotion Installation Partner Green CHIP Dealer we Green CHIP Dealer will at our option either repla
17. led in your original Prius This warranty cannot be transferred to your Product installed in another vehicle and is void if the Product is removed from your vehicle without authorization from A123 If you are the original purchaser of the Product you may transfer this warranty to a new owner of the vehicle in which the Product was originally installed provided the new owner contacts A123 during the Warranty Period in order to register the Product Under no circumstances shall such transfer extend the duration of the Warranty Period Your Product is the first generation of commercially available new technology and may be modified or improved over time in subsequent versions of the Product A123 reserves the right to make changes to future versions of the Product without assuming any obligation to make such changes on your previously installed or manufactured Product Your Product has been engineered and tested by A123 during product development to operate effectively and without detrimental effect to your Prius A123 does not anticipate detrimental interaction with your Prius or other defects in the Product However as A123 gains additional field experience with the Product if A123 determines that there is a systematic defect in the Product A123 may initiate a voluntary Product recall In the event of a voluntary Product recall A123 will reimburse you the price you paid for your Product amortized over the Warranty Period and will ensure that your Prius is
18. oblem See Chapter 4 Troubleshooting the LS PCM for more information Figure3 LS switch Monitoring the L5 PCM Operation 1 The Prius Energy Monitor displays the L5 PCM s State of Charge SOC when the LS is in operation The SOC indicates the L5 5 available electrical energy as shown in Figure 4 Green is high charge blue is between high and low charge and purple is low charge The LS PCM communicates status information to the Prius When a new piece of information is sent by the LS PCM the Energy Monitor display may flicker or return to the Energy Monitor home screen if a different screen is being displayed This is normal 2 The Energy Monitor SOC indicator reflects the SOC of the Prius NiMH battery when the LS PCM has fully discharged or has been turned off State of Charge SOC indicator 100 Figure 4 Energy Monitor Display Page 11 12 Do not shut off the L5 PCM while driving except an emergency Shutting off the LS PCM while driving clear the vehicle settings such as cruise control and could result in serious injury or death NOTE Due to the interactions between the LS PCM and the vehicle s display the center panel can return to the Energy Monitor home screen during LS PCM information updates This could interrupt the user while browsing through other functions For example if the user is adjusting the temperature using the touch panel d
19. r consequential damages or do not allow disclaimers of implied warranties or limitation on the duration of implied warranties so the above limitations and exclusions may not apply to you For warranty claims contact A123Systems Hymotion Product Support Call 1 877 246 7438 Email hymotionsupport a123systems com Hours Monday through Friday 10 am to 6 pm Eastern Time Warranty claims are processed through A123Systems For warranty service you must bring your vehicle to an authorized Green CHIP dealer for inspection and repair Page 25
20. rd could result in serious injury or death Page 3 Page 4 WARNING WARNING WARNING Ground Fault Circuit Interrupter The L5 PCM must be charged from an electrical outlet or an extension cord equipped with GFCI Failure to do so could result in serious injury or death Spare Tire Removal Installation of the LS PCM a Toyota Prius requires the permanent removal of the spare tire Do not store the spare tire in the vehicle It could become a projectile and result in serious injury or death Objects in the Spare Tire Well Do not place objects in the spare tire well between the vehicle and the LS PCM These objects could become unsafe projectiles in a collision and result in serious injury or death In addition these objects could obstruct the cooling air intake of the LS PCM and result in improper cooling and impaired performance Vehicle Load The installed LS PCM adds 200 pounds to the weight of your vehicle as noted on the label attached to the driver side door jamb See Figure 1 for the location of the vehicle load label Factor in the weight of the LS PCM when loading your vehicle Do not exceed the total load capacity of your vehicle Doing so could unbalance your vehicle and damage the tires or deteriorate your steering capability Refer to the Prius Owner s Manual regarding the total load capacity of your vehicle CAUTION LOAD CARRYING CAPACITY REDUCED Modifications to this vehicle have reduced th
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