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
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.
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
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!
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
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.
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.
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!
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.
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
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 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 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.
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!
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 .
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).
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".
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
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!
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.
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.
Oh snap! You do tesla video too!! Diff subscribing ty! I'm an extricate car enthusiast. Love the engineering and I can see how to make it more effective ill be installing lithium modules in my 2005 prius. 1900$ but I bought the car for 900, def worth it. Considering these cars get 350k+ miles
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.
2005 Prius has a repetitive indication of a Hybrid Battery problem. I bought a rebuilt Hybrid Battery from a national auto parts company with a 3 yr warranty. Initially replaced the original prius Hybrid Battery and 12v battery in February of 2017. It appeared to resolve the problem. Three months later, in May of 2017, it indicated an OBDII code of P0A80 and I replaced the Hybrid Battery again under warranty. Both times the replacement battery worked well initially. But it rarely achieved 100%. Usually the dash indicated 80% at best. Two weeks ago, I got the red triangle and P08A0 code, cleared it and drove with no problem, just noticed that the Hybrid Battery indicated on the dash that it dropped to 10% - 20% very quickly, especially if parked overnight or for a few days. But with driving returned to about 60 to 80% of its strength. Yesterday I had a Red Triangle on the dash and these OBDII codes: 1. P0A80 (Replace Hybrid Battery Pack), 2. P2505 (EMC Power Input Signal), 3. P0403 (EGR Circuit), and 4. P000A (Engine Position System Performance). My question is what is really wrong? It is difficult to believe I have gotten two bad replacement batteries back to back. I think there is something in the system that is slowly draining these batteries. I would expect them to reach 100% after a little driving at least when first installed. But with them dying after only a few months, something else must be wrong that has not been giving me a code, unless the key problem is reflected in the P2505 code. If there is a problem within the ECU, is there a likely part or parts that I could test and replace if bad without replacing the entire ECU? The car is in Florida with only 175,000 miles on it. It has been driven about 5,000 miles this year. Thank you.
The battery level is not supposed to go up to 100% while driving, it typically will be in the 40-60% range. This way there is room for energy storage while decelerating and power for acceleration. The new Prius we have stays around 40%. All of those DTCs are related to a bad hybrid battery. The hybrid battery supplies power to the DC-DC converter. The DC-DC converter charges the 12V battery. The 12V battery supplies power to the ECM. If the 12V battery power is low (because it is not being charged properly by the hybrid battery), it will trigger the rest of the codes your vehicle has. Rebuilt hybrid batteries are nothing more than someone else's bad battery that someone has replaced a few bad cells )with other used cells they hope are better then the ones being replaced). It is very possible to have another bad hybrid battery. Best wishes.
Thanks for the detailed overview. In summary the system de-energizes itself but I wouldn't stake my life on it. Have you a video on the computer that controls the engine, MGs, and inverter/converter, accessory charger, etc? That must be the heart of the system!
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.
I do have a question for you. I have a 2007 gen II Prius. There is a man on youtube who has hooked up 1000 watt/2000 watt surge pure sine wave inverter to the 12-volt side of the system as an emergency backup for his home. (See ua-cam.com/video/Uh02JLAP3lo/v-deo.html) My concern is if the draw is enough to harm the 12-volt inverter side of my Prius if I follow suit. It seems from your description that and what I have read that the charging of the 12-volt auxiliary batter is more of a low amperage charging system that keeps a float charge on the battery. Is this a correct assumption? Do you know the maximum amperage draw on the Prius's 12-volt inverter side of the system without damage? And how long an auxiliary draw be maintained without damage? Thank you
Power in must equal power out. If you want 1000 Watts output at 120 volts, the maximum current output is only 8.33 amps. That will not power very many items in a home at the same time. Furthermore, providing 1000 Watts from the Prius charging system and 12V battery (at 14 Volts with the vehicle powered up) would require 71.4 amps of current. The maximum output of the DC-DC converter is 100 amps (and it will run very hot if forced to run at that level for a long time). The vehicle alone will draw 50 - 70 amps with the engine running, cooling fans on, electric water pumps running, etc. It will draw less current while the 12V system is drawing down the 201.6V battery, but the engine must start to recharge the 201.6V battery. In other words, the 1000 watt inverter idea may work for short time periods, but it will not be able to sustain 1000 watts continuously. The DC-DC converter will run too hot at those levels and start to turn down its output rate to preserve itself. It is not a good idea if you need a long time power supply. It should never be run just from the 12V battery without the hybrid system powered on; the 12V AGM battery will be damaged. By the way, the high voltage Ni-Mh battery of a standard Prius has less capacity in ampere-hours (21Ah) than the 12V battery does (30Ah). This means that trying to connect to the high voltage battery will result in even less power. I hope that helps
Thanks for the answer. One more question - what is the charging amperage max to the 12-volt battery from the built-in charging system? So, with this in mind, I think I can get by with a 600-watt pure sine wave for periods, especially if I am only running 100 watts or less AC loads - so the efficiency should be ok and allow the car's system to run as necessary. Also, when the car is stationary without A/C or lights, etc, there should be ample headroom for a small load. Also, due to the large output capacity of the genset (50kW) for the 200V battery and drivetrain, it would seem that connecting into the 200v side of the system would be efficient due to the capacity of the MG unit to charge and keep this battery available for such a load as well as the standard load for the car. AS you know, however, a 200v to 12-volt dc converter would be a custom build or difficult to find, thus the 12 volt seems to be the answer.
Actually, are called you a professor well-deservedly. and I wish the honor that I am one of your students. Can we know what are the common problems or malfunctions in this system?
good evening or morning! i have highlander hybrid 3.300 front wheel drive and my ICE engine wouldnt stop when ideling! Gas engine never stalls although it should! Thank 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 ua-cam.com/video/_V9PiOpaxyE/v-deo.html
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!
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.
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?
Thank you very much for this video! Wish chevy would do what toyota did and partner up with a university to teach its chevy volt system. But since they dont even post the volt's battery voltage on the wiki page i doubt that will happen anytime soon. Thanks again!
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!
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: ua-cam.com/video/_V9PiOpaxyE/v-deo.html
I wish this was required viewing for the mechanics in my area. Can't seem to find anybody who really knows how to properly work on my '04 Prius. Wish I could take your classes, so I can handle things myself.
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%
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
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?
Hi! Great content.I would like to know, when working on deconnecting the high voltage power on the vehicle, which PPE should be used for this task? Rubber gloves? Goggles? Arc Flash clothing?thanks
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 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.
Good Morning Professor, I have a 2nd Gen Prius. I was driving in traffic, accelerated hard and the vehicle shuddered and shut down. The dealership said my Inverter/converter was bad, so I purchased a used Hybrid system and from it swapped IPM card and Capacitor block first. I still had same condition/error (P0A94). I then installed the Reactor and Boost Converter Module. The original BCM had evidence of the device smoking on the mating connector. At this point the car started and would go into gear, however the "triangle of death" came on (No more P0A94, now P0A78). I was able to clear the P0A78, but every time I re-start the car it returns. It seems if I clear it, all systems function, but id I do not clear it the traction batt starts to deplete while driving. My OBD II code reader says P0A78 is low phase A output. I have to try to fix it myself as I can afford the $4700 quote the dealership gave me. Please let me know what you think of these conditions.
Hi, did you use the recommended heat transfer grease under the IPM, reactor and boost converter module? It also needs to be applied with a squeegee at a certain thickness. There are templates available for the grease application. If you did not have the POA78 until after you worked on it, you probably have a bad connection somewhere. Phase A output is one of the three orange wires that goes to each of the two motors in the transaxle. I would double check your connections for cleanliness and proper torque.
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
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!
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
Приус это шедевр! Высокий импульс творческой мысли, смелое шерение , чудесное поплощение!!! Быть добру!!! Таёта I LOVE YOU!
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!
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
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 is well above my head and I will need to watch this couple of times. Very well presented and useful information!
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
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!
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.
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.
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!
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
absolutely concise. loved it.
15 nuff nuffs showed their stupidity by thumbs downing this material. WHAAAAT?
+Gods Phone Thank you!
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.
Fantastic job my friend. Learned a lot on that electrical system. Gives me a way better understanding on how the car works
Simply the best video, no comparison. This is truly professional.
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.....
Outstanding demonstration for this HV. WSU Automotive Technology 'Great job'.
Bonjour, je suis très ravie de la vidéo , je vous remercie car vos explications sont très claires , je continue à vous suivre.
Congratulation for the helpful explanation. It´s good to learn from another Professor.
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.
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!
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.
Amazing! So well explained. Thank You Professor. It is a marvelous travel trough my favorite vehicle.
Thank you very much
Thank you sir, this is what I was looking for.
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).
John, that clock says 11:25. It's either time for lunch or time for bed. Great video.
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".
This was very informative, I really need full knowledge of all components and buttons in the jump start box!!
thank you for detailed explanation of the toyota system . . . so very completely well understood . . .
Thank you!
Very informative video that demonstrate how the electric system works on a Prius. Thanks.
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.
Great effort. Thank you very much
Many thanks indeed for this awesome video... 👌
ThanK you so much... You're amazing and your explanations are quite unique and understandable... Thanks a bunch
Thank you
Amazing layout wonderful knowledge simple straight to the point all amazing matainance tips and reminders
So cool! What a great teacher. Wish I could be a student here!
Thank you!
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
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!
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.
Absolutely an awesome video. Thank you very much for this.
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!
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.
Take a breath! )) Great review though clear and accurate!
+diioriog Thank you!
Oh snap! You do tesla video too!! Diff subscribing ty! I'm an extricate car enthusiast. Love the engineering and I can see how to make it more effective ill be installing lithium modules in my 2005 prius. 1900$ but I bought the car for 900, def worth it. Considering these cars get 350k+ miles
Thanks for watching!
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!
excellent video , it make me aware of the parts of my Lexus ct which has the same engine as the Prius
Thank you!
Excellent video. Very informative.
And the mistery is gone !!, Thankss a lot
Thank you!
Excellent presentation. Thank you.
Great information on the way to the last second!
Thank you!
2005 Prius has a repetitive indication of a Hybrid Battery problem. I bought a rebuilt Hybrid Battery from a national auto parts company with a 3 yr warranty. Initially replaced the original prius Hybrid Battery and 12v battery in February of 2017. It appeared to resolve the problem.
Three months later, in May of 2017, it indicated an OBDII code of P0A80 and I replaced the Hybrid Battery again under warranty. Both times the replacement battery worked well initially. But it rarely achieved 100%. Usually the dash indicated 80% at best.
Two weeks ago, I got the red triangle and P08A0 code, cleared it and drove with no problem, just noticed that the Hybrid Battery indicated on the dash that it dropped to 10% - 20% very quickly, especially if parked overnight or for a few days. But with driving returned to about 60 to 80% of its strength. Yesterday I had a Red Triangle on the dash and these OBDII codes:
1. P0A80 (Replace Hybrid Battery Pack),
2. P2505 (EMC Power Input Signal),
3. P0403 (EGR Circuit), and
4. P000A (Engine Position System Performance).
My question is what is really wrong? It is difficult to believe I have gotten two bad replacement batteries back to back. I think there is something in the system that is slowly draining these batteries. I would expect them to reach 100% after a little driving at least when first installed. But with them dying after only a few months, something else must be wrong that has not been giving me a code, unless the key problem is reflected in the P2505 code.
If there is a problem within the ECU, is there a likely part or parts that I could test and replace if bad without replacing the entire ECU? The car is in Florida with only 175,000 miles on it. It has been driven about 5,000 miles this year. Thank you.
The battery level is not supposed to go up to 100% while driving, it typically will be in the 40-60% range. This way there is room for energy storage while decelerating and power for acceleration. The new Prius we have stays around 40%.
All of those DTCs are related to a bad hybrid battery. The hybrid battery supplies power to the DC-DC converter. The DC-DC converter charges the 12V battery. The 12V battery supplies power to the ECM. If the 12V battery power is low (because it is not being charged properly by the hybrid battery), it will trigger the rest of the codes your vehicle has.
Rebuilt hybrid batteries are nothing more than someone else's bad battery that someone has replaced a few bad cells )with other used cells they hope are better then the ones being replaced). It is very possible to have another bad hybrid battery. Best wishes.
Thanks for the detailed overview. In summary the system de-energizes itself but I wouldn't stake my life on it. Have you a video on the computer that controls the engine, MGs, and inverter/converter, accessory charger, etc? That must be the heart of the system!
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!
You rock homie. Thanks for this tutorial.
Its a great explanation. Thanks for the help
Glad it was helpful!
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.
thank you so much for such for actually explaining this unit in such detail.
Thank you!
I do have a question for you. I have a 2007 gen II Prius.
There is a man on youtube who has hooked up 1000 watt/2000 watt surge pure sine wave inverter to the 12-volt side of the system as an emergency backup for his home. (See ua-cam.com/video/Uh02JLAP3lo/v-deo.html)
My concern is if the draw is enough to harm the 12-volt inverter side of my Prius if I follow suit.
It seems from your description that and what I have read that the charging of the 12-volt auxiliary batter is more of a low amperage charging system that keeps a float charge on the battery. Is this a correct assumption?
Do you know the maximum amperage draw on the Prius's 12-volt inverter side of the system without damage? And how long an auxiliary draw be maintained without damage?
Thank you
Power in must equal power out. If you want 1000 Watts output at 120 volts, the maximum current output is only 8.33 amps. That will not power very many items in a home at the same time. Furthermore, providing 1000 Watts from the Prius charging system and 12V battery (at 14 Volts with the vehicle powered up) would require 71.4 amps of current. The maximum output of the DC-DC converter is 100 amps (and it will run very hot if forced to run at that level for a long time). The vehicle alone will draw 50 - 70 amps with the engine running, cooling fans on, electric water pumps running, etc. It will draw less current while the 12V system is drawing down the 201.6V battery, but the engine must start to recharge the 201.6V battery. In other words, the 1000 watt inverter idea may work for short time periods, but it will not be able to sustain 1000 watts continuously. The DC-DC converter will run too hot at those levels and start to turn down its output rate to preserve itself. It is not a good idea if you need a long time power supply. It should never be run just from the 12V battery without the hybrid system powered on; the 12V AGM battery will be damaged. By the way, the high voltage Ni-Mh battery of a standard Prius has less capacity in ampere-hours (21Ah) than the 12V battery does (30Ah). This means that trying to connect to the high voltage battery will result in even less power. I hope that helps
Thanks for the answer.
One more question - what is the charging amperage max to the 12-volt battery from the built-in charging system?
So, with this in mind, I think I can get by with a 600-watt pure sine wave for periods, especially if I am only running 100 watts or less AC loads - so the efficiency should be ok and allow the car's system to run as necessary. Also, when the car is stationary without A/C or lights, etc, there should be ample headroom for a small load.
Also, due to the large output capacity of the genset (50kW) for the 200V battery and drivetrain, it would seem that connecting into the 200v side of the system would be efficient due to the capacity of the MG unit to charge and keep this battery available for such a load as well as the standard load for the car.
AS you know, however, a 200v to 12-volt dc converter would be a custom build or difficult to find, thus the 12 volt seems to be the answer.
Good to learn that this prius has a inverter AC.
Actually, are called you a professor well-deservedly. and I wish the honor that I am one of your students. Can we know what are the common problems or malfunctions in this system?
It's looks like Power Electrical. 3 phase Motor drives by VFD. Thank you Professor.
good evening or morning! i have highlander hybrid 3.300 front wheel drive and my ICE engine wouldnt stop when ideling! Gas engine never stalls although it should! Thank 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 ua-cam.com/video/_V9PiOpaxyE/v-deo.html
excellent is there a video for the plug in version?
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!
Top notch explanation!
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.
great demonstration..Could you have the isolation relays wrongly labled.the arc aresting component on mine is across the positive isolation relay.
Excellence explanation video, thanks.
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?
Thank you very much for this video! Wish chevy would do what toyota did and partner up with a university to teach its chevy volt system. But since they dont even post the volt's battery voltage on the wiki page i doubt that will happen anytime soon. Thanks again!
Thank you sir,very informative! God bless!
Your are great teacher thank you
Impressive instruction
Thank you
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!
Thank you for the great video!
Thank you!
Awesome! Thank you for this.
+Arthur Chaput Thank you!
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: ua-cam.com/video/_V9PiOpaxyE/v-deo.html
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.
That's a very informative video, Thanks.
I wish this was required viewing for the mechanics in my area. Can't seem to find anybody who really knows how to properly work on my '04 Prius. Wish I could take your classes, so I can handle things myself.
+Mike Burgess Thank you!
@JrgrimWoW Hi, thank you. I must have forgotten to mention the "Flux Capacitor" and the "Jiga-Watts" of power. :)
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%
Excellent video! Would you recommend buying a hybrid vehicle for the average driver? What would be the criteria to whether buy a hybrid or not?
Nice set up.
Thank you!
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)
感恩了解，謝謝分享！
Hi Mr how are you
Your job is very good ❤❤❤❤
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.
Great video!!! When replacing the transmission let's say, Is " removing the service plug grip" good enough to work under the hood? Thanks.
Hi! Great content.I would like to know, when working on deconnecting the high voltage power on the vehicle, which PPE should be used for this task? Rubber gloves? Goggles? Arc Flash clothing?thanks
Thank you! You should use Class 0 gloves and Safety glasses/goggles.
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
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.
Good Morning Professor,
I have a 2nd Gen Prius. I was driving in traffic, accelerated hard and the vehicle shuddered and shut down. The dealership said my Inverter/converter was bad, so I purchased a used Hybrid system and from it swapped IPM card and Capacitor block first. I still had same condition/error (P0A94). I then installed the Reactor and Boost Converter Module. The original BCM had evidence of the device smoking on the mating connector. At this point the car started and would go into gear, however the "triangle of death" came on (No more P0A94, now P0A78). I was able to clear the P0A78, but every time I re-start the car it returns. It seems if I clear it, all systems function, but id I do not clear it the traction batt starts to deplete while driving. My OBD II code reader says P0A78 is low phase A output. I have to try to fix it myself as I can afford the $4700 quote the dealership gave me.
Please let me know what you think of these conditions.
Hi, did you use the recommended heat transfer grease under the IPM, reactor and boost converter module? It also needs to be applied with a squeegee at a certain thickness. There are templates available for the grease application. If you did not have the POA78 until after you worked on it, you probably have a bad connection somewhere. Phase A output is one of the three orange wires that goes to each of the two motors in the transaxle. I would double check your connections for cleanliness and proper torque.