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Interfacing the

Manzanita Micro PFC-50

to the

Toyota RAV4-EV

by the New Jersey RAV4-EV Team:

Duke Ahn

Lisa Mikulynec

David, Drew, and Joy Turock

Wally Urbanski

Revision 3 – July 31, 2007

Overview

The Manzanita Micro PFC-50 is a highly versatile electric vehicle charging device that accepts a wide range of input

voltages and currents. Connected to a 240VAC/50A circuit, it can fully charge the Toyota RAV4-EV in about 2.5 hours --

less than half of the time required by the charger supplied with the vehicle. The PFC-50 can be connected to a

120VAC/15A or 120VAC/20A circuit as well, allowing any conventional electrical receptacle to serve as a charging

station. A full charge from a 120VAC/15A circuit is accomplished in approximately 18 hours.

Since the RAV4-EV can be driven while it is being charged by the PFC-50, coupling the charger with a mobile generator

converts the RAV4-EV into a serial Plug-in Hybrid Electric Vehicle with 100 miles of all-electric range (i.e., a PHEV-100)

and extends its continuous driving range by several hundred miles.

We describe a procedure for interfacing the PFC-50 with the RAV4-EV, and present our prototype implementation of the

PHEV conversion / range extender.

Acknowledgments

William and Doug Korthof provided us with invaluable advice, without which we’d still be pouring through the Toyota

service manuals. Tom Dowling was also instrumental in guiding us through several PHEV conversion engineering issues.

Caveats

This procedure exposes you to hazardous and potentially fatal electrical current. If you’re not a licensed electrician

familiar with AC and DC high voltage systems, you will need to find one to perform the procedure for you. In addition,

this procedure is not authorized by Toyota, voids your warranty, and should be regarded as experimental. If you choose

to perform the procedure, you must assume all liability for personal injury and/or damage to your vehicle. Otherwise,

we respectfully require that you don’t read any further. Sorry about the legal disclaimers, but we don’t want anyone

getting hurt.

Summary of content (19 pages)

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Interfacing the Manzanita Micro PFC-50 to the Toyota RAV4-EV by the New Jersey RAV4-EV Team: Duke Ahn Lisa Mikulynec David, Drew, and Joy Turock Wally Urbanski Revision 3 – July 31, 2007 Overview The Manzanita Micro PFC-50 is a highly versatile electric vehicle charging device that accepts a wide range of input voltages and currents. Connected to a 240VAC/50A circuit, it can fully charge the Toyota RAV4-EV in about 2.5 hours -less than half of the time required by the charger supplied with the vehicle.
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Calibrating Comments The text below describes our implementation, based on the Korthof design. We made a number of choices along the way that may or may not be consistent with your personal preferences and charging needs. Most parts of our procedure may be modified, with a few notable exceptions. Where something must be implemented exactly as specified, it is so indicated.
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The “Procedure:” Step 1. Remove the traction battery service plug (labeled the Service Prug [sic]). This is located behind the driver’s seat under the floor carpeting. Be sure that you aren’t wearing anything metal that could drop into the compartment after you’ve pulled the plug (e.g., neck chain, etc.) Replace the metal door covering the service plug once you have removed the plug.
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Step 2. Remove the negative (black; labeled “-“) battery terminal from the 12v battery under the hood. Step 3. Have a cup of coffee or a glass of water while you wait the mandatory 15 minutes required by the Toyota service manual for appropriate capacitance discharge to occur in the vehicle’s electrical systems. Step 4. Thread both #8 wires through the conduit. This is most easily accomplished if the conduit is laid out straight before the conduit is routed under the vehicle.
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Step 6. Drill an appropriate sized hole for the marine connector (part 860010) using the template found in the package. Connect one end of the 4/3AWG cord to the marine connector. Mount the connector as shown in the picture. Connect the other end of the 4/3 cord to the surface mount 14/50 receptacle. Secure the 14/50 to the metal vent chamber as in the pictured in Step 8, below. There are screw holes at the top of the vent chamber; you don’t need to puncture the chamber to get a secure fit. Step 7.
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Step 8. Terminate the wires at this end of the conduit on the load side of one of the GE breakers. Note that one terminal on the breaker is labeled “+” and the other “-“. Place the red-insulated #8 wire on the positive (“+”) terminal and the black-insulated #8 wire on the negative (“-“) terminal. Step 9. Cut away a piece of the plastic large enough to match the ridges in the top and bottom of the front face of the GE breaker as in the picture.
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Step 10. Cut two feet of the #8AWG red and two feet of the #8AWG black cable from the opposite side of the conduit. Solder one side of these cable pieces to the Anderson SB175 connector. Note: The Anderson connector terminals are large. We had to use a propane torch to achieve sufficient heat to melt the solder. It’s easier to hold Anderson lug vertical, heat it, fill it 2/3 of the way up with molten solder, and then quickly insert the wire.
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Step 16. Use the torx wrench to remove the cover of the electronics compartment. Marvel for a moment at the elegant simplicity of the engineering in this electric vehicle. Important note: It is imperative that you keep the inside of the electronics compartment free of all dirt, debris, metal shavings, wire trimmings, and tools. When the car is re-energized, extremely high voltages will be present in here. Leaving a screw driver or even a few strands of misplaced wire inside could create a huge problem.
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Step 18. Using the box cutter, carefully cut a one-inch hole in the rubber boot on the right side of the electronics compartment under the hood. Cut off any excess conduit from your run, so that the conduit terminates adjacent to the hole in the boot. Alternatively, you might want to use a tighter seal (note the upper right hand corner), although this complicates removal of the top to the electronics unit.
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Step 19. Insert the red and black wires through this opening, and carefully and gently pull the wire inside the electronics compartment. Do not apply force to the plastic connectors near the boot opening. Route the wire around the lower right corner of the electronics compartment as in the picture. Step 20. Measure and trim the wires so that there is enough length to reach the breaker positioned as in the picture. Terminate these wires on the “line” side of the second GE breaker.
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Step 21. Solder an eye terminal to one end of the red wire trimmed off in Step 20. Step 22. Solder an eye terminal to one end of the black wire trimmed off in Step 20. Note: Perform the next two steps exactly as indicated. Do not attempt to connect your cables to any other terminals other than the ones indicated, even though it might appear to make sense to do so. Connection as indicated is necessary for the RAV4-EV’s computers to be aware of the power from the PFC-50. Step 23.
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Step 24. Using the 12mm socket, and an extension, remove the nut shown in the picture below. This one is tricky. If you have big hands, find an agreeable volunteer with long, thin fingers to reach down and remove the nut. Insert the eye terminal you just soldered to the black cable on this bolt. Replace the nut and tighten. Inspect the connection to ensure that no metal from the eye terminal you have just installed is in contact with anything else nearby.
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Step 25. Route the red wire from the eye terminal as shown in the picture to the second GE circuit breaker. Trim off any excess wire being extremely careful to do the cutting outside of the electronics compartment so that no copper fragments end up in the compartment. (We placed the electronics compartment’s cover over the space before making each wire cut.) Attach the end of the red wire to the positive (“+”) terminal of the GE breaker. Place the protective wire covering along the length of the red wire.
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copper fragments end up there. Attach the end of the black wire to the negative (“-”) terminal of the GE breaker. Place the protective wire covering along the length of the red wire. Cable strap the wire to hold it in place. Step 27. Turn the breaker “ON” (red is exposed when on; green when off). Step 28. Replace the cover on the electronics compartment. Using the torx wrench tool, tighten down the screws that hold it in place. Step 29.
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Calibrating the PFC-50 The first step in using the PFC-50 is to perform a one-time calibration. To do this: Step 1. Charge the car to full using the standard Toyota charger. If you prefer to have the Manzanita charge to the bottom of your sag point, wait 12 hours before continuing to Step 2, so that your RAV’s traction battery will sag to 90% or thereabouts. Step 2. Set the Manzanita’s DIP switches #1 and #7 to ON; everything else OFF.
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Charging with the PFC-50 Step 1. Turn off the GE breaker in the cargo compartment Step 2. Turn off the PFC-50 breaker Step 3. Turn the PFC-50 AMPS knob counterclockwise until it stops Step 4. Mate the Anderson connectors Step 5. Plug in the PFC-50, either through the marine receptacle, or directly Step 6. Start the car. This step is critical. Car must be in “READY” mode during charging to turn on the battery cooling fans when the battery temperatures rise. Step 7.
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RAV4-EV PHEV-100 / Range Extender Notes We’ve empirically determined that the RAV4-EV doesn’t mind receiving energy from the PFC-50 while the car is in motion, including during regenerative breaking and when the “EB” mode is selected for coasting regeneration. If you have a powerful enough generator and you’re willing to limit your highway speed to between 55 and 60MPH, the RAV4-EV may be driven continuously between gasoline refills.
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