L5 Plug-In Conversion Module Service Manual
Contents
1. Please wait while the wizard searches y USB Serial Converter Cancel Figure C 3 Search screen C 2 Release 01 401567 001 Appendix C Installing the Tripp Lite Adapter Driver Install the Adapter Driver 8 Walt while the wizard searches for the correct location This could take several minutes Figure C 4 18 displayed Found New Hardware Wizard Completing the Found New Hardware Wizard The wizard has finished installing the software for e USB Serial Converter Click Finish ta clase the wizard Figure C 4 Completed screen 9 Select the Finish button NOTE Use Window s Device Manager to discover the communication port that was assigned to the USB Serial adapter Make note of the assigned communication port Installation Manual C 3 Appendix C Installing the Tripp Lite Adapter Driver Install the Adapter Driver C 4 Release 01 401567 001 Appendix D Installing the IFM Downloader Install the Downloader Install the downloader as follows 1 Retrieve from the ftp website 2 Copy download exe download msi and download cfg to a local directory 3 Run download msi Figure D 1 is displayed Welcome to the DOWNLOAD Setup Wizard The installer will quide you through the steps required to install DOWNLOAD on your computer Click Next to continue WARNING This computer program is protected by copyright law and international treaties Unauthorized duplication or2. Strip back a 1 4 of an inch 6 35mm of insulation from CAN H and CAN L 6 CUT 12V POWER a Cut 12V Power to Battery ECU B11 CONNECTOR pin 1 7 inches 177 8 mm from E SIDE the back face of the B11 Strip back 1 4 of an Inch 6 35mm of insulation from both cut ends 3 2 Release 01 401567 001 Chapter 3 Connecting the Wiring Harness Connecting the CAN and Power Table 3 1 CAN and power 7 15 CONNECTOR V1 7 uwM JE a Use illustration as a reference for the following steps L5 CONNECTOR V1 NOTE Reference Table A 1 on page 1 for the connector V1 pinouts 8 BARREL CRIMP 1 a Double crimp V1 pin 5 to Vehicle Side of B11 pin 1 using the non marked end of barrel crimp A123Systems Part Number 401680 001 9 RECONNECTING 12V POWER a Insert heat shrink tubing on the connector side of B11 pin 1 Attach other end of 12V power connector with barrel crimp 1 marked with a red stripe 10 BARREL CRIMPS 2 amp 3 CONNECTOR F SIDE CAN E 4 h mms 5 a Secure the barrel crimps A123 4 Systems Part Number 401682 001 the connector side of B11 pins 18 amp 19 Insert heat shrink tubing on both wires Crimp the connector side CAN to the L5 V1 connector as follows B11 pin 19 to V1 pin 9 B11 pin 18 to V1 pin 10 Installation Manual 3 3 Chapter 3 Connecting the Wiring Harness Connecting the CAN and Power Table
3. a Remove the bolt and luggage hold D ring Remove the fir tree fastener from the deck trim side panel Remove the 2 bolts from the deck trim side panel Undo the 6 clips and remove the deck trim side panel Disconnect the lighting connector 13 REMOVE THE BATTERY CARRIER BRACKET a Remove the 7 bolts b Remove the battery carrier bracket 2 4 LIGHTCONNECTOR CLIPS O _ QO BOLTS 0 tae Release 01 401567 001 Chapter 2 Installation Preparation Preparing for the Installation Table 2 1 Pre installation steps UN I4 REMOVE THE BATTERY CARRIER PANEL a Remove the 3 bolts and 2 nuts b Remove the battery carrier panel 15 REMOVE THE FRONT SCUFF PLATE LH a Remove the scuff plate by pulling up firmly 16 REMOVE THE COWL SIDE TRIM BOARD LH a Remove the trim board by pulling up firmly 17 THE REAR SCUFF PLATE LH a Remove the scuff plate by pulling up firmly Installation Manual 2 5 Chapter 2 Installation Preparation Preparing for the Installation Table 2 1 Pre installation steps ENL NEM ON 18 REMOVE THE CENTER PILLAR LOWER GARNISH LH a Detach the lower half of the B Pillar trim 19 REMOVE THE INSTRUMENT PANEL REGISTER ASSEMBLY LH a Remove the instrument panel register by pulling firmly 20 REMOVE THE LOWER INSTRUMENT FINISH PANEL SUB ASSEMBLY Remove the 2 screws Disconnect the hood control c
4. AA 7 L5 Plug In Conversion Module Service Manual 49977 A lt ZZ FT lt 123 SYSTEMS LS NANOPHOSPHATE LI A amp AY 23 123 Systems Inc www ai23systems com Release 01 SYSTEMS www hymotion com 401567 001 Copyright 2008 A123Systems Inc All rights reserved DOCUMENT NOTICE The information contained in this manual is the property of A123 Systems Inc A123 Systems and is subject to change without notice A123 Systems 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 information contained herein is adequate and sufficient for user s particular use It is the further responsibility of each user to ensure that all applications of A123 Systems products are appropriate and safe based on conditions anticipated or encountered during use This document does not create any additional obligation for A123 Systems and does not constitute additional warranties and representations The A123 Systems logo is a trademark and a service mark of A123 Systems Inc Release 01 401567 001 Contents Installation Kit and Tools Hir VOU RR ms 1 1 G F To eio au _______________ __ __ 1 7 Installation Preparation 2 1 Preparing e Insa JN ec 2 2 Connecting the Wiring Harness Connecting the
5. Cover connection in electrical tape for isolation Secure integrated fuse to vehicle harness Reconnect the 510 pin into the skid control ECU and replace the floor vent Installation Manual 3 9 Chapter 3 Connecting the Wiring Harness Connecting the EV Button Pin Connecting the EV Button Pin Table 3 4 provides Instructions for connecting the EV button pin Table 3 4 EV button pin ee HE 1 ROUTE THE WHITE EV WIRE Vl pin 15 a Route the remaining white wire behind the lower center panel trim Route the wire above the cabin air filter toward the Hybrid Control ECU Secure the wire 2 INSERT THE L5 EV SIGNAL WIRE V1 PIN 15 INTO THE HYBRID CONTROL ECU NOTE Reference Figure 3 1 on page 3 11 for the following steps a Locate the H16 connector and gently pull the white tab out of connector 1 8 of an inch 3 2mm to release the pin lock Trim the right hand side key feature on the EV signal wire pin before inserting into the H16 pin 27 Reattach the plug into the HV ECU 3 10 Release 01 401567 001 Chapter 3 Connecting the Wiring Harness Connecting to the HV ECU Connecting to the HV ECU Figure 3 1 illustrates the HV ECU and its location in the vehicle INSERT RECEPTACLE AND WIRE Figure 3 1 HV ECU Installation Manual 3 11 Chapter 3 Connecting the Wiring Harness Installing the Enable Switch Installing the Enable Switch Table 3 5 provides instructions for installing
6. Chapter 2 Installation Preparation Preparing for the Installation Table 2 1 Pre installation steps mn 6 DISCONNECT THE AUXILIARY BATTERY FROM THE GROUND CHASSIS GROUNDW a Disconnect the 12V auxiliary E N battery from the chassis AC a ground under the right rear floorboard Locate wire away from ground 7 REMOVE THE TONNEAU COVER a Remove the cover 8 REMOVE THE SERVICE PLUG GRIP WARNING Be sure to wear insulating gloves for the following procedure a Slide the lever of the service plug grip to the up position Remove the service plug grip while turning the lever to the left SERVICE PLUG GRIP NOTE Do not operate the power switch after removing the service plug grip This could damage the vehicle s control ECU 9 REMOVE THE NO 1 FLOOR BOARD CLIPS _ a Fold down the back seat b Remove the 2 bolts that secure the luggage hold D rings Remove the 5 clips and rear floor board Installation Manual 2 3 Chapter 2 Installation Preparation Preparing for the Installation Table 2 1 Pre installation steps 10 REMOVE THE REAR DECK TRIM COVER a Remove the deck trim cover by pulling up firmly 11 REMOVE THE REAR SIDE SEAT BACK FRAME LH a Remove the bolt from the right rear seat back side bolster Slide up to undo the 3 joints and remove the right rear seat back side bolster I2 REMOVE THE DECK TRIM PANEL LH
7. Oe tion 10 SECURE THE HIGH VOLTAGE LEADS IN PARALLEL WITH THE OEM BATTERY a Attach the negative lead to the front terminal location b Attach the positive lead to the rear terminal location NOTE Torque 3 4 N m 35 kgf cm 30 In bf 11 INSTALL THE BATTERY CARRIER PANEL AND GROUND WEB Position the Battery Carrier Panel Install the Ground Web onto the rear carrier panel stud Secure the Carrier Panel with 3 10mm bolts and 2 10 mm nuts 12 CONNECT THE COMMUNICATION AND BRIDGE PLUG CONNECTORS PLUG a Attach the CAN and Interlock bridge plug to the PCM harness using a zip tie Connect the bridge plug to the vehicle side harness 13 INSTALL THE BRACE FOR THE OEM BATTERY a Remove the 2 12mm bolts b Position the brace and secure with the same OEM hardware 4 4 Release 01 401567 001 Chapter 4 Installing the L5 PCM to the Vehicle Installing a Charge Port and Exhaust Duct Table 4 1 Installing the L5 PCM emen Mame 14 PREPARE NO 1 FLOOR BOARD FOR REINSTALLATION a Trim the reinforcement tabs b Install a replacement fir tree connector IS ATTACH THE LOAD LABEL TO THE VEHICLE S DOOR JAM a Attach the load label as illustrated Installing a Charge Port and Exhaust Duct Install the 120V charge port and exhaust duct as described in Table 4 2 Table 4 2 Installing the charge port and exhaust duct Description Illustration 1 DETACH THE L
8. 3 1 CAN and power IIl BARREL CRIMPS 4 amp 5 VEHICLE SIDE CAN a Double crimp the vehicle side CAN wiring using barrel crimps A123 Systems Part Number 401682 001 as follows B11 pin 19 to V1 pin 12 B11 pin 18 to V1 pin 11 Cover all the connections with heat shrink tubing pinching together the empty end of tubing on the barrel crimps 4 amp 5 12 BARREL CRIMPS 6 amp 7 SYSTEM MAIN RELAY CONNECTIONS a Cutthe yellow and green wires 7 inches 177 8mm from the back face of the System Main Relay connector Strip back a 1 4 of an inch 6 35mm of insulation from each end and insert 1 5 heat shrink tubing on the wires Double crimp the vehicle side of the system main relay yellow and green wires with the L5 V1 harness using barrel crimps A123 Systems Part Number 401682 001 as follows System main relay yellow to V1 pin 7 System main relay green to V1 pin 6 Secure the other end of the barrel crimps 6 amp 7 to the connector side of the system main relay harness Verify proper color combinations Cover all connections with heat shrink tubing 3 4 ii NEL tn Barrel Crimps 4 amp 5 Barrel Crimps 6 amp 7 Connector Side 4 Position System Main Relay Connector Release 01 401567 001 Chapter 3 Connecting the Wiring Harness Connecting the CAN and Power Table 3 1 CAN and power NM 13 INSULATE THE L5 AND OEM WIRE HARNESS a Bundle all connected w
9. CAN and Powers aa assssaana asaaasaashaqakawkasaaashassashasakhawakaawnskasasasaaskhuyaa 3 1 Connecting the Start Button nnne nnne 3 8 Connecting the ABS Remote WIIG amp a sisse eene 3 9 Conmecting ne EV u lu un an FM 3 10 Connecting to the HV 3 11 Installms the Enable Swie __ _ 3 12 Installing the L5 PCM to the Vehicle Installing the L5 4 1 Installing a Charge Port and Exhaust Duct 4 5 Check Out Procedures Completing the Check ss 5 1 Foil MI Id UU 5 2 Sl O iy T uuu us uamata _ __ 5 2 Dine a uuu m DI ___ __ __6_ ______ ___ 5 4 Diagnostic Procedures 5 6 and CONNIE 5 6 H 0009 5 7 Global Variable Dein MOUS 5 7 Contactor Quo uuu ulula _____ __ 5 8 9 ERR 5 8 Faulty T ODHe SCIO uuu ullu ne ne ____ BADE 5 9 Pack 5 9 Charge Cord Connection 5 0 Firmware Update Procedures Ji hii y uuu usapu _
10. DIAGONAL CUTTER NEEDLE NOSE PLIERS 13 8 10 12 MM RATCHETING WRENCHES e Installation Manual 1 9 Chapter 1 Installation Kit and Tools Required Tools Table 1 2 Required tools METRIC WRENCH UNIBIT EXTENSION AND 1 2 INCH UNIBIT 9 16 INCH UNIBIT 3 8 INCH DRIVE RATCHET 3 8 INCH DRIVE AND 8 INCH EXTENSION 1 10 Release 01 401567 001 Chapter 1 Installation Kit and Tools Required Tools Table 1 2 Required tools 19 3 8 AND 1 4 INCH METRIC SOCKET SETS MAGNETIC PICK UP TOOL AND MIRROR SCREW DRIVERS PHILIPS AND STRAIGHT ELECTRICAL TAPE 13 4 INCH HOLE SAW Installation Manual 1 11 Chapter 1 Installation Kit and Tools Required Tools Table 1 2 Required tools 24 LATCH HOOKS McMaster Part 8836T42 25 SLINGS McMaster Part 9073T402 CRIMPING TOOL CHANNEL LOCK 909 THE CRIMPER 27 HEAT GUN 28 SHOP VACUUM 1 12 Release 01 401567 001 Chapter 1 Installation Kit and Tools Required Tools Installation Manual 1 13 Chapter 1 Installation Kit and Tools Required Tools 1 14 Release 01 401567 001 Chapter 2 Installation Preparation This chapter Includes the following section Safety Overview on page 2 1 Preparing for the Installation on page 2 2 Safety Overview WARNING WARNING WARNING CAUTION N CAUTION The L5 PCM operates at a high voltage Improper handling could cause an electric shock
11. Follow all precautions while servicing the vehicle Do not touch the high voltage connectors or terminals for five minutes after removing the service plug grip Do not reconnect the service plug while you are servicing the vehicle The LS energy is high enough to sustain an ARC flash Personal Protective Equipment PPE is required while servicing the vehicle Wait at least 90 seconds after disconnecting the cable from the negative 12V battery terminal before servicing the vehicle This prevents activating the air bag or seat belt pretensioner The LS PCM weighs 180 pounds Take precaution when lifting the LS PCM Installation Manual 2 1 Chapter 2 Installation Preparation Preparing for the Installation Preparing for the Installation Table 2 1 provides L5 PCM pre installation instructions Table 2 1 Pre installation steps Description Illustration 1 REMOVE THE NO 2 FLOOR BOARD a Release the locks by turning their knobs Remove the No 2 floor board 2 REMOVE THE REAR DECK FLOOR BOX a Remove the floor box 3 REMOVE THE REAR FLOORBOARDS a Remove the right side floor board No 3 Remove the left side floor board No 4 4 REMOVE THE DECK FLOOR BOX Unscrew the 10mm plastic nut Remove the nut Remove the deck floor box 5 REMOVE THE JACK ASSEMBLY AND SPARE TIRE a Turn knob counter clockwise b Remove the jack c Remove the spare tire 2 2 Release 01 401567 001
12. distribution of this program any portion of it may result in severe civil ar criminal penalties and will be prosecuted to the maximum extent possible under the law Figure D 1 Install Shield 4 Select the Next button to begin installing the downloader Figure D 2 is displayed Installation Manual D 1 Appendix D Installing the IFM Downloader Install the Downloader Select Installation Folder The installer will install DOWNLOAD in the following Folder install in this folder click Nest To install ta a different new existing folder enter ane below ar click Browse Folder C Program Fiesi DOWNLOADY Y ou can install the software on the following drives Volume Disk 1 H 37 8 lt gt Figure D 2 Customer information 5 The destination folder location defaults to C Program Files DOWNLOAD Keep this location 6 Select the Next button Figure D 3 is displayed Contirm Installation The installer is ready to install DOWNLOAD on your computer Click Next to start the installatian Cancel Previous M ext Figure D 3 Destination folder D 2 Release 01 401567 001 7 Select the Next button to confirm the installation The program installs as shown in Figure D 4 Installing DOWNLOAD DOWNLOAD 15 being installed Writing system registry values Appendix D Installing the IFM Downloader i ERES Cancel Previous dex Figure D
13. on page 4 5 Installing the L5 PCM NOTE Verify that you have documented the L5 PCM serial number on the customer repair order before installing the unit to the vehicle Table 4 1 provides installation instruction for the L5 PCM Table 4 1 Installing the L5 PCM 1 REMOVE THE L5 PCM FROM SHIPPING CRATE a Remove the bolts at the top 4 corners of the L5 PCM Attach the lifting hooks McMaster Part 8836T42 Attach the slings onto the lifting hooks MeMaster Part 9073T402 NOTE Note the serial number from the side panel of the L5 PCM before lowering it into the vehicle TIP Secure the L5 cables Installation Manual 4 1 Chapter 4 Installing the L5 PCM to the Vehicle Installing the L5 PCM Table 4 1 Installing the L5 PCM Oe Mei 2 ATTACH THE EXHAUST MANIFOLD a Lower the L5 PCM onto the work surface Attach the gasket to the exhaust manifold Attach the exhaust manifold to the L5 PCM using 8 fir tree plug fasteners 3 PREPARE THE RIGHT SIDE MOUNTING Remove the ABS control unit connector Remove 2 12 mm bolts Remove 1 10 mm bolt Remove the ABS control unit from vehicle 4 PREPARE THE FRONT MOUNTING a Remove and discard the 2 12 mm bolts from the back mounting of the OEM battery 5 POSITIONING THE MATS a Position the noise vibration mats on the left and right trunk floor area 6 LOWER THE L5 PCM INTO THE VEHICLE a Rotate the L5 PCM through the hatch opening
14. the system enable switch Table 3 5 System enable switch EN 1 REMOVE THE SMALL BLANK ACCESSORY PANEL FROM THE LOWER TRIM PANEL a Push out the blank panel from the trim panel 2 MOUNT THE ENABLE SWITCH AND LED INTO PANEL a Drill a 9 16 15 mm and 1 4 inch 6 38 mm hole into the blank accessory dash panel Mount the enable switch and LED indicator into the drilled holes Crimp the male spade terminal to the red LED indicator Crimp the female spade terminal to the black LED indicator FEMALE a Mount the negative ring terminal of the LED to a ground location behind the accessory dash panel 3 12 Release 01 401567 001 Chapter 3 Connecting the Wiring Harness Installing the Enable Switch Table 3 5 System enable switch EN Baton 5 RE INSTALL THE UPPER AND LOWER DASH PANELS a Feed the blue brown orange and black wires through the small panel opening before securing the lower panel Connect the brown and black wires to the LED indicator Connect the orange and blue wires to the 2 silver posts on the switch Insert the connected accessory panel and wires into the lower dash Installation Manual 3 13 Chapter 3 Connecting the Wiring Harness Installing the Enable Switch 3 14 Release 01 401567 001 Chapter 4 Installing the L5 PCM to the Vehicle This chapter Includes the following sections e Installing the L5 PCM on page 4 1 e Installing a Charge Port and Exhaust Duct
15. to System Main Relay Harness green wire Yellow 41 cm System Pre Charge Relay Signal 12V Connects to System Main Relay Harness yellow wire Black w ring term 65 cm Interlock Ground Connects to OEM Battery ECU mounting screw Vehicle Ground Yaw wed wack em CANT comecar o EV Button Signal Connects to H 14 pin 27 ABS Remote Power Connects to 10 pin 7 Installation Manual A 1 Appendix A Installation Harness Pin Outs Pin Assignment Table A 2 Release 01 401567 001 Appendix B Installing PEAK CAN Adapter Driver Install the Adapter Driver Install the PEAK CAN to USB adapter drivers as follows l Insert the supplied CD into a PC or laptop 2 Install the PEAK CAN to USB adapter s drivers 3 Select Finish to complete the installation 4 PCAN PCL dll from the CD to a local directory Path to the file is as follows CD Drive Develop Windows PCI PCAN PCI dll 5 Remove the CD Installation Manual B 1 Appendix Installing PEAK CAN Adapter Driver Install the Adapter Driver B 2 Release 01 401567 001 Appendix C Installing the Tripp Lite Adapter Driver Install the Adapter Driver Install the Tripp Lite adapter driver as follows 1 Connect the adapter to a USB port on a laptop Figure C l is displayed on your laptop Found New Hardware Wizard Welcome to the Found New Hardware Wizard This wizard helps you install software for usb se
16. 01 5 VEHICLE INSTALLATION 400772 001 HARNESS s 6 PRIUS MOUNT BRACKET REAR 400941 001 LEFT 7 PRIUS MOUNT BRACKET REAR 400690 001 RIGHT 1 2 Release 01 401567 001 Chapter 1 Installation Kit and Tools Installation Kit Table 1 1 Installation kit contents Payee Item Description Part Number TRP Mustaton part Number SCREW MACHINE HEX HEAD 900021 2809 M10 X1 5 40 MM LG STEEL PHOSPHATE COAT CONICAL a WASHER 10 1 5 FLANGE NUT 900030 0587 10 SCREW MACHINE HEX HEAD M8 X 1 25 30 MM LG STEEL ZN PLATED CONICAL WASHER 13 MM HEX 11 ZIP TIES 400760 001x10 401149 001x20 12 CHARGE PORT 400789 001 13 ALUMINUM BACKING PLATE 400439 001 Installation Manual 1 3 Chapter 1 Installation Kit and Tools Installation Kit Table 1 1 Installation kit contents Payee Item Description Part Number 14 SCREW MACHINE BUTTON HEAD M4X0 7 40 MM LG STAINLESS 18 8 PLAIN FULLY THREADED HEX 2 5 MM to secure Marinco charge port 900019 5603 401153 001 401150 001 900030 0361 15 CLAMP FOR CHARGE PORT 16 FIR TREE PANEL FASTENER 5 16 X 3 1 LG 17 NUT HEX M6X1 0 10 MM SOCKET SIEEL ZN PLATED CONICAL WASHER 18 PLUG FASTENER FIR TREE 400982 001 NYLON 0 70X0 54 19 PLUG CAN AND INTERLOCK 401129 001 BRIDGE 1 4 Release 01 401567 001 I I 0 I Chapter 1 Installation Kit and Tools Installation Kit Table 1 1 Installation ki
17. 3 e Voltage Error 4 CAN Communication Fault 5 Battery Temperature Error 6 AC PreCharge Fault 7 Crash Sensor Set Off 8 Service Plug Not Seated 9 BMS Auto Address Fault 10 e Low Battery Cell Voltage 11 Battery CAN Communications Fault 12 e Vehicle CAN Communications Fault 13 e 12 Vehicle Battery Low 14 Over Current Fault 15 Module Over Voltage Fault 16 Contactor Sequence The following table provides a diagnostic for a contactor sequence issue L5 Module remains in Contactor sequence is Swap V1 pin 6 amp 7 to correct state 2 and does not backwards Variable 2 15 seen the polarity issue on the progress to state 6 and before Variable 1 installation harness state 5 upon startup Unbalanced Pack The following table provides a diagnostic for an unbalanced pack issue min cell voltage and Battery pack 1s unbalanced Replace the battery pack max cell voltage differ by more than 0 05V 5 8 Release 01 401567 001 Chapter 5 Check Out Procedures Diagnostic Procedures Faulty Connection The following table provides a diagnostic for a faulty connection issue Problem Solution EV button wire has faulty Verify that 12V is present at V1 pin 15 with respect to connection chassis ground when vehicle is powered on If 12V is present drive the vehicle until EV mode 15 achieved Pack Temperatures The following table provides a diagnostic for a pa
18. 3 1 Connecting the Start Button Interlock on page 3 8 Connecting the ABS Remote Wire on page 3 9 Connecting the EV Button Pin on page 3 10 Connecting to the HV ECU on page 3 11 Installing the Enable Switch on page 3 12 Connecting the CAN and Power Table 3 1 provides Instructions for connecting the CAN and power Table 3 1 CAN and power 1 LOCATE THE OEM WIRING CONNECTORS AT THE LEFT OF THEOEM SYSTEM MAIN HV BATTERY RELAY CONNECTOR BATTERY ECU ASSEMBLY a Disconnect the system main relay connector Remove the clamp and disconnect the Battery ECU Assembly Connector BATTERY ECU ASSEMBLY CONNECTOR 2 REMOVE THE HARNESS CLAMPS FROM THE HARNESS a Remove the harness clamps HARNESS CLAMPS b Straighten the harness bends 2279 N x Installation Manual 3 1 Chapter 3 Connecting the Wiring Harness Connecting the CAN and Power Table 3 1 CAN and power ee e 3 PREPARE OEM HARNESS FOR INTEGRATION a Remove 10 Inches 254mm of electrical tape and sleeve from battery harness NOTE This leaves the small diameter corrugated loom intact BATTERY ECU CONNECTOR PINOUT B11 pinouts are as follows B11 POS 1 12V Power B11 POS 18 CAN H B11 POS 19 CAN L CUT THE CAN H AND CAN L WIRES a Cut the CAN H and CAN L wiring pins 18 amp 19 7 inches 177 8 mm from back face of B11 Remove 3 inches 76 2 mm of outer insulation and EMI shielding from both pairs of CAN wires
19. 4 Begin installation 8 Select the Next button when the installation completes Figure D 5 is displayed Installation Manual Install the Downloader D 3 Appendix D Installing the IFM Downloader Install the Downloader Installation Complete DOWNLOAD has been sucesstully installed Click Close to exit Figure D 5 Installation complete 9 Select the Close button to exit the downloader D 4 Close Release 01 401567 001 Appendix D Installing the IFM Downloader Install the Downloader Installation Manual D 5 Appendix D Installing the IFM Downloader Install the Downloader D 6 Release 01 401567 001
20. 86 Pre Upgrade Environment Verify the following conditions are met prior to installing the firmware in the BMS 2 3 4 Turn off the vehicle Remove the service plug Plug in the vehicle to the electrical outlet Verify the Tripp Lite adapter drivers are installed See Appendix C for adapter installation details Verify the IFM Downloader is installed See Appendix D for installation details Running the A123 System s Firmware Install A123 System s firmware as follows l 6 2 From Windows go to START All Programs Shortcut to DOWNLOAD exe Figure 6 2 is displayed Release 01 401567 001 Chapter 6 Firmware Update Procedures Firmware Update Procedure 1 DOWNLOAD File Interface Protocol Security Options Specials 2 a AS ert n o0 x iene t NC s 1 Cg LM fare EX 3 F L0 a Upload Verify EN Step S Figure 6 2 Download screen 2 Under Interface select the radio button for RS232 Figure 6 3 is displayed R5232 Bits per Second Data Bits 115200 gt 8 gt Parity Set PLC H Stop Bits Figure 6 3 RS232 parameters 3 On the Bits per Second pull down Select 115200 4 On Data Bits pull down Select 8 5 the Parity pull down Select N 6 On the Stop Bits pull down Installation Manual 6 3 Chapter 6 Firmware Update Procedures Firmware Update Procedure 6 4 Select On the COM P
21. EFT SIDE OF THE REAR BUMPER COVER a Remove the 2 phillip screws from the top of the bumper cover Remove the 10mm bumper fastener from the LR wheel well 2 DRILL HOLES FOR CHARGE SOCKET a Drill 1 1 3 4 inch hole for the charge port receptacle Drill 2 3 16 inch holes for the charge port mounting screws Place charge port tunnal thru opening to locate the port location NOTE Template is used for illustration purposes and Is not included with the kit Installation Manual 4 5 Chapter 4 Installing the L5 PCM to the Vehicle Installing a Charge Port and Exhaust Duct Table 4 2 Installing the charge port and exhaust duct Oe NNNM 3 SECURE THE CHARGE RECEPTICLE a Passthe Marinco charge receptacle with gasket through the opening Secure the Marinco charge receptacle to the backing plate with the 2 provided stainless steel screws SECURE THE CHARGE CORD TO THE RECEPTICLE a Passthe charge cord through the front area of the cabin vent CHARGE CORD Secure the charge cord into the charge port receptacle and secure with a hose clamp INSTALL THE EXHAUST DUCT a Attach the exhaust duct to the exhaust manifold Secure the exhaust duct to the stud with an M5 Keps nut 6 RECONNECT THE 12V GROUND WIRE 4 6 Release 01 401567 001 Chapter 5 Check Out Procedures This chapter Includes the following sections e Completing the Check List on page 5 1 e Diagnostic Pro
22. Lower the L5 PCM into the trunk of vehicle Reposition the noise vibration mats as required 4 2 mnis ada EXHAUST MANIFOLD Release 01 401567 001 Table 4 1 Installing the L5 PCM Chapter 4 Installing the L5 PCM to the Vehicle Installing the 5 PCM ma T 7 SECURE THE L5 PCM TO VEHICLE a Install 2 black hardened M8 1 25x30 mm bolts at the front of the L5 PCM and the back of the OEM battery mounting locations Install 2 black hardened M8 1 25x30 mm bolts to the right side of the PCM securing ABS control unit in place Reconnect the ABS connection 8 LEFT SIDE MOUNTING HOLE PROCEDURE a Install the LH mount bracket to the left side of the L5 PCM Use a Unibit with extension to drill a 1 2 inch 12 7 mm hole for the left side L5 PCM mount and the LH mount bracket Favor the left side of the openings as indicated in the illustration when drilling the holes Insert 2 M10 1 5 X 40 mm bolts into the 1 2 inch 12 7 mm holes NOTE Vacuum the drill shavings after drilling the holes 9 SECURE THE 2 M10 1 5 X 40 MM BOLTS ON LR OF L5 PCM a Remove the 2 clips and 1 screw that secure the plastic tray from the back underside of the car Attach the washers and nuts to the 2 M10 1 5 X 40 mm bolts Reinstall the plastic tray Installation Manual 4 3 Chapter 4 Installing the L5 PCM to the Vehicle Installing the 5 PCM Table 4 1 Installing the L5 PCM
23. ___ ___ _ _ _ ________ 6 1 ina are Update 6 1 PRS US 6 2 PSUs pap de Jy an 6 2 Running the A123 System 5 Filrmwatre 6 2 C onmpletmp te ___ ______ 4 4 6_ 6 6 4 Appendix A Pin Assignment Table L uuu u HH 1 Installation Manual Contents Appendix B Install the Adapter ____ ____ 0 6 1 Appendix AN Ti Adapter Di y a 1 Appendix D Jusi allied Ot AC Ee a gi uuu uu uu u aQ D 1 li Release 01 401567 001 Chapter 1 Installation Kit and Tools This chapter Includes the following sections e Installation Kit on page 1 1 Required Tools on page 1 7 CAUTION The Hymotion L5 Plug In Conversion Module PCM must be installed by A123 Systems certified technicians Installation Kit The contents of the installation kit are described in Table 1 1 Table 1 1 Installation kit contents Item Description Part Number w J aJ 1 L5 PCMINSTALLATION KIT 401137 001 2 CARDBOARD BOX 401134 001 Installation Manual 1 1 Chapter 1 Installation Kit and Tools Installation Kit Table 1 1 Installation kit contents Payee Item Description Part Number RP Mustaton part Number 3 EXHAUST MANIFOLD 40088 1 001 4 GASKET EXHAUST MANIFOLD 401086 0
24. able Pull panel firmly to reveal plug connection Detach all plug connectors smart key dimmer etc 2 REMOVE THE UPPER INSTRUMENT FINISH PANEL SUB ASSEMBLY a Pull the finish panel to reveal the POWER button connector Disconnect the POWER button connector Remove the finish panel by pulling firmly 2 6 Release 01 401567 001 Chapter 2 Installation Preparation Preparing for the Installation Table 2 1 Pre installation steps ton 22 THE CENTER LOWER INSTRUMENT FINISH PANEL a Remove the fir tree clip from the right side MIR TREE Detach the accessory outlet connector Remove the center lower finish panel CLAWS QO 23 REMOVE THE NO 2 INSTRUMENT PANEL REGISTER ASSEMBLY RH a Remove the instrument panel register by pulling firmly CLIPS CLAWS CO 24 REMOVE THE GLOVE COMPARTMENT DOOR ASSEMBLY a Push the slide inward to allow pins to pass frame Remove the glove compartment strut by detaching it from lower pivot Pull the glove compartment away from hinge 25 REMOVE THE FINISH END PANEL a Remove the finish end panel from the vehicle Installation Manual 2 7 Chapter 2 Installation Preparation Preparing for the Installation 2 8 Release 01 401567 001 Chapter 3 Connecting the Wiring Harness This chapter Includes the following sections Connecting the CAN and Power on page
25. arness NOTE Refer to Installing the L5 PCM to the Vehicle on page 4 1 for more information Release 01 401567 001 10 12 Installation Manual Chapter 5 Check Out Procedures Completing the Check List Plug the charge cord into the vehicle and proceed as follows a Connect the PEAK CAN and ODBII adapters together as shown in Figure 5 1 b Connect the PEAK CAN adapter to the USB port on the laptop c Connect the ODBII adapter to the ODBII port on the vehicle d Initiate the L5 Install software utility NOTE Refer to the Charge Cord Connection on page 5 9 for more information e Verify the following variables battery soc is between 25 and 75 percent C f Verify the three brake lights are dimly lit during the charging phase C Press START with foot on brake a Verify the vehicle does not start with charge cord connected C Disconnect the charge cord Press and hold the brake pedal for 5 seconds and release a Press the start button within 30 seconds and without the brake pedal depressed The green illumination on the switch is displayed b Wait 5 seconds and press the start button again The amber illumination on the switch is displayed c Verify the vehicle dash display illuminates with default settings C d Verify the following variables state 2 fault message 0 C NOTE Refer to Global Variable Definitions on pag
26. cedures on page 5 6 Completing the Check List Please supply the following Information Module ID Install Facility Technician Install Date Vehicle VIN Customer Name Customer Contact Installation Manual 5 1 Chapter 5 Check Out Procedures Completing the Check List 5 2 Required Items The following items are required to run the checkout procedure A laptop running Windows XP operating system An available USB port Peak System PCAN to USB adapter This adapter can be purchased from the following website http www peak system com db gb pcanusb gb html part number PEH 002021 ODBII to Serial adapter PEAK CAN i ODBII TO SERIAL Figure 5 1 PEAK CAN adapter ODBII to Serial adapter Stationary Test The stationary tests are as follows l Verify the state of charge of the 12V battery a Trickle charge the 12V battery if it is below 12V Reinstall the orange OEM and Hymotion L5 service plugs C Verify all vehicle connections Connect the bridge plug to the Hymotion vehicle side harness C a Start the vehicle Verify the vehicle goes to READY mode without any issues or CITOIS C NOTE Refer toWiring and Connections on page 5 6 for more information b Press and hold the brake pedal Verify all brake lamps lit C Turn off the vehicle Remove the bridge plug Connect the Hymotion L5 harness to the vehicle h
27. ck temperature issue Battery pack Blocked air inlet vent or Verify there is no blockage in the temperatures are out of exhaust duct air inlet vent or inside the exhaust range duct Verify air flow is exiting the Hymotion exhaust duct Charge Cord Connection The following table provides a diagnostic for a charge cord issue ac on is not The charge cord connection Verify the charge cord is properly displayed is faulty connected Installation Manual 5 9 Chapter 5 Check Out Procedures Diagnostic Procedures 5 10 Release 01 401567 001 Chapter 6 Firmware Update Procedures This chapter Includes the following sections e Introduction on page 6 1 e Firmware Update Procedure on page 6 1 Introduction The L5 PCM Battery Management System BMS keeps track of key operational parameters that occur during the charge and discharge cycle The BMS could require firmware upgrades This chapter details installing firmware on the BMS Firmware Update Procedure This section describes the required items and the pre install environment necessary for upgrading the firmware Installation Manual 6 1 Chapter 6 Firmware Update Procedures Firmware Update Procedure Required Items The following items are required to upgrade firmware in the BMS A laptop running Windows XP operating system An available USB port Tripp Lite USB to Serial adapter Figure 6 1 Tripp Lite adapter A123System supplied firmware
28. e 5 7 for state and fault message information NOTE Locate the variables prius hv contact and prius contact2 in the L5 Install software utility before proceeding with step 12 Press the start switch for the 3rd time while holding the brake pedal Leave the Hymotion L5 enable switch in the ON position 5 3 Chapter 5 Check Out Procedures Completing the Check List START switch illumination disappears READY mode illuminates on the dash display a The software displays the HV contactor sequence while starting the vehicle Verify Variable 1 is displayed before Variable 2 Variable 1 prius hv contact C Variable 2 prius hv contact2 C NOTE If Variable 2 is displayed before Variable 1 refer to Contactor Sequence on page 5 8 b Turn on the Air Conditioner and the headlights c Verify the following variables system enable C state 5 C fault message 0 C battery soc is between 25 and 75 percent C pack power between 300W and 10000W after 2 minutes C box on C min cell voltage between 2 8V and 3 6V C max cell voltage between 2 8V and 3 6V C min and max cell voltages are within 0 05V of each other C NOTE Refer to Unbalanced Pack on page 5 8 for more information p batt v between 170V to 245V C battery am
29. ector P11 Cut the wire from P11 pin 6 approximately 3 inches 76 2mm T Barrel Crimp 9 from the back face of P11 Strip back 3 4 of an inch 6 35mm of insulation from the connector side and insert heat shrink over wire Attach the L5 V1 pin 13 to the connector side of P11 pin 6 Cover with 1 5 inches of heat shrink tubing using the barrel crimp A123 SYSTEMS PART NUMBER 401682 001 NOTE Make sure to isolate unused harness side of P11 pin 6 with additional heat shrink 2 INSULATE AND ROUTE WIRES a Cover the start switch connection with OEM rubber insulation and secure any extra wire Route the remaining blue and white wires to the right of the IP support 3 8 Release 01 401567 001 Chapter 3 Connecting the Wiring Harness Connecting the ABS Remote Wire Connecting the ABS Remote Wire Table 3 3 provides instructions for connecting the ABS remote wire Table 3 3 ABS remote wire 1 REMOVE THE WHITE AIR DEFLECTOR HOUSING BELOW THE STEERING COLUMN a Remove the fir tree connector b Pull the housing firmly down and to the left 2 LOCATE THE SKID CONTROL UNIT LOWER DASH a Remove the bottom most connector from the skid control unit Locate the large pink wire on the S10 pin 3 SKID CONTROL ECU CONNECTION a Strip back insulation 1 2 inch into pink wire S10 pin 1 1 5 inches from back face of S10 with Hymotion V1 pin 16 Solder in parallel Do not cut pink wire
30. include L5 PCM diagnostic procedures for various issues Wiring and Connections The following table provides diagnostics for wiring and connection issues Relay clicks are not heard when starting the vehicle A system DTC fault is posted Only one or two relay clicks are heard and a DTC is posted Three clicks are necessary to start the vehicle PreCharge negative HV and positive HV contactors Start switch not operational Communication error between HV ECU and OEM HV Battery Vehicle starts but DTC is posted and engine turns on right away with full radiator fans 5 6 Service plug is not inserted or seated correctly Contactor signals are not properly connected Disconnected interlock ground at OEM battery pack Wrong connection at the start switch 1 e Hymotion ground connected to vehicle harness and not the switch Fault in the wiring connections to the start switch CAN signals are wired backwards CAN H to CAN L is switched on one of the CAN channels CAN signals are improperly crimped resulting in a loose connection Power to OEM Battery ECU is not present and ECU is receiving no power due to a faulty connection Reinsert the service plug Cycle vehicle on off 5 times to clear fault Check continuity of contactor signals Repair any wire faults Check continuity of ground to start switch P11 pin 6 Switch should be grounded when bridge plug is inserted Check proper
31. ires from the connector V1 and secure with electrical tape Replace the rubber protective sleeve from the OEM harness Include the black wire from the connector V1 pin 8 verifying that the ring terminal 1 close to the connector B11 14 INSTALL THE OEM AND THE L5 HARNESS INTO VEHICLE a Reconnect the 3 battery ECU Harness Clamps assembly connectors Attach both OEM harness clamps to the harness Install the harness into the vehicle Secure the L5 V1 pin 8 ground terminal to the battery ECU mounting screw 3 3 Nm 291 16 15 ROUTE THE BRAKE LIGHT INDICATOR Route the brake light indicator up the shock support structure using the recommended tie points Secure the brake light indicator wire V1 pin 4 red conductor in 1 4 of an inch 635mm corrugated split loom to the inner wheel well Installation Manual 3 5 Chapter 3 Connecting the Wiring Harness Connecting the CAN and Power Table 3 1 CAN and power 16 LOCATE THE BRAKE LAMP CONNECTOR Locate the left brake light connector R9 Strip back the insulation on the blue Brake Light wlre R9 pin 5 1 5 Inches from back Connector face of R9 connector Solder red wire from Hymotion V1 pin 4 in parallel Cover connection in electrical tape for isolation Secure loose wiring and replace connector R9 into the brake light assembly 17 ROUTE THE L5 HARNESS VEHICLE REAR a Secure the L5 wire harness to the OEM wi
32. orientation and continuity of CAN signals Verify power 15 present on B11 pos 1 Release 01 401567 001 Chapter 5 Check Out Procedures Failure to Start Diagnostic Procedures The following table describes a diagnostic for a vehicle failure to start issue Vehicle does not start Check for power on pin 5 displays a warning anda and 16 with respect to chassis DTC ground Should see a minimum of 9 6V anda maximum of 14 6V Inspect under the dash board ABS fuse and connections 1f power is not present on V1 pin 16 Check for ground to L5 PCM module Global Variable Definitions Global variable definitions are as follows l Installation Manual The state variables Start Q Initialize Standby 2 AC Connected 3 Charge phase Complete 4 Running with Charge 5 Running without Charge 6 Pack Discharged 7 Pack Running Discharged 8 Pack Running Discharged Recharging 9 AC Cord Connected 10 AC Cord Connected Pack Balancing 11 AC PreCharge 12 Fault 99 If power and ground are present and CAN is not present than vehicle CAN is backwards CAN H and CAN L swapped on both channels A loose CAN connection on the vehicle or L5 module side of the CAN bus p Chapter 5 Check Out Procedures Diagnostic Procedures 2 The fault_message variables are as follows Current Sensor Fault 1 BMS Fault 2 e DC DC Converter Fault
33. ort pull down Select the COM port where the adapter is connected NOTE Use Window s Device Manager to discover the communication port that was assigned to the USB Serial adapter Make note of the assigned communication port Select OK The RS232 screen closes Reference the Download screen that is displayed in Figure 6 2 on page 6 3 a Select the Open File button b Select the program file having an H86 extension Completing the Installation Complete the installation as follows l Connect the serial end of the Tripp Lite adapter to the DB9 connector port on the driver s side of the pack Reference the Download screen that is displayed in Figure 6 2 on page 6 3 a Select the Identity button Selecting the Identity button tests the communications to the controller NOTE Do not proceed until proper communications have been established b Select the Download button This starts the download procedure and takes approximately 10 seconds c Select the Run button when the download has completed This completes the Installation and the charging process resumes Release 01 401567 001 Appendix A Installation Harness Pin Outs The installation harness pin assignments are described in this appendix Pin Assignment Table Table A 1 provides the installation harness pin assignments Table A 1 Pin assignments enem BELT NN aee s Green 41 cm System Main Relay Signal 12V Connects
34. p hrs between 0 1 and 25 C d Probe for 12V on the Hymotion harness connector V1 pos 15 NOTE Refer to Faulty Connection on page 5 9 for more information Drive Test The following steps require that the vehicle is driven in a test loop while a technician monitors the L5 Install software utility variables Avoid highways on the drive test Verify the Internal Combustion IC engine turns on at least once during the drive cycle 5 4 Release 01 401567 001 Chapter 5 Check Out Procedures Completing the Check List The following verifies the Hymotion 5 module s power flow and EV mode engagement a Drive the vehicle on a flat 5 10 mile test loop until the following conditions are true engine warm C pack power reaches a minimum of 7000W during electrical acceleration C Fuel economy at the end of test loop exceeds 80 mpg C The following verifies pack temperatures are read correctly while the vehicle 15 running a Verify the following conditions are true min cell temperature is within 10 C of max cell temperature C air inlet temp 15 within 30 C of max cell temperature C box temp is less than 55 C C NOTE Refer to Pack Temperatures on page 5 9 if temperatures are out of range 949 Installation Manual Chapter 5 Check Out Procedures Diagnostic Procedures Diagnostic Procedures The following sections
35. re harness running along the top left rear shock tower 3 6 Release 01 401567 001 Table 3 1 CAN and power 18 ROUTE THE L5 HARNESS DOOR SILLS Chapter 3 Connecting the Wiring Harness Connecting the CAN and Power Oe AND A PILLAR a Secure the L5 harness along the rear and front left door sills using the OEM harness clamps Secure the L5 harness along the OEM wire harness located alongside the A Pillar support column using zip ties NOTE Take extra care to avoid interfering with the emergency park brake assembly 19 ROUTE THE L5 HARNESS INSTRUMENT PANEL a Route the L5 harness to the OEM dimmer connector with the following wires V1 pin 3 brown V1 pin 16 blue V1 pin 14 orange Route the remainder of the L5 harness along the top of the instrument panel and secure it Installation Manual Hymotion V1 pin 3 16 14 3 7 Chapter 3 Connecting the Wiring Harness Connecting the Start Button Interlock Connecting the Start Button Interlock Table 3 2 provides Instructions for connecting the start button Interlock Table 3 2 Start button interlock 1 BARREL CRIMP 9 START BUTTON INTERLOCK CONNECTION _ White w Blk Str P11 pin 6 Peel back a5 inch 127mm section of the OEM rubber insulation from the Start Button harness Locate the white black stripe wire toward the center of the connector P11 pin 6 Start Button Conn
36. rial converter If your hardware came with an installation CD SEA or floppy disk insert it now What do you want the wizard to do Install the software automatically Recommended e Install from a list or specific location Advanced Click Next to continue TE Figure C 1 New hardware wizard 2 Select the Install from a list or specific location radio button 3 Select the Next button Figure C 2 is displayed Installation Manual C 1 Appendix C Installing the Tripp Lite Adapter Driver Install the Adapter Driver Found New Hardware Wizard Please choose your search and installation options Pha Was S Search for the best driver in these locations Llse the check boxes below to limit or expand the default search which includes local paths and removable media The best driver found will be installed Search removable media floppy CD ROM Include this location in the search en J Dont search will choose the driver to install Choose this option to select the device driver from a list Windows does not quarantee that the driver you choose will be the best match for your hardware I Figure C 2 Installation options 4 Select Search for the best driver in these locations radio button 5 Select nclude this location in the search check box 6 Browse to the A123System s supplied location 7 Select the Next button Figure C 3 1 displayed
37. t contents 20 BRACE OEM BATTERY PRIUS 2 EXHAUST DUCT CONNECTOR 22 ZIPLOCK BAG 23 HEX NUT M5x0 8 8 24 HEATSHRINK 3 16 ID 12 LONG 25 HEX NUT M10x1 5 10MM Installation Manual Chapter 1 Installation Kit and Tools Installation Kit Table 1 1 Installation kit contents Payee Item Description Part Number 26 BARREL STEP DOWN CRIMP 22 18AWG 38054 2 401680 001 401682 001 401683 001 401685 001 401953 001 401084 001 27 BARREL BRAZED SEAM 22 18AWG 30260 28 SCOTCHLOCK MALE TERMINAL 1 29 SCOTCHLOCK FEMALE 1 TERMINAL 1 30 CAUTION LABEL 31 NOISE VIBRATION RIGHT 1 6 Release 01 401567 001 Chapter 1 Installation Kit and Tools Required Tools Table 1 1 Installation kit contents Payee Item Description Part Number Description TRP Mhustration part Number mE 4 Required Tools The required tools are described in Table 1 2 Table 1 2 Required tools 1 INSULATED GLOVES INSPECTED FOR LEAKS AND DAMAGES MULTI METER CORDLESS DRILL Installation Manual 1 7 Chapter 1 Installation Kit and Tools Required Tools Table 1 2 Required tools 4 CORDLESS IMPACT WRENCH ADAPTORS FOR IMPACT WRENCH 3 8 AND 1 4 INCH DRIVE 6 FLASH LIGHT 7 SOLDERING IRON 8 SOLDER 1 8 Release 01 401567 001 Chapter 1 Installation Kit and Tools Required Tools Table 1 2 Required tools WIRE STRIPPERS 10 PRY BAR
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