Hybrid Interface 2013

Discussion in 'Prius PHEV Plug-In Modifications' started by NortTexSalv04Prius, Jun 9, 2013.

  1. planetaire

    planetaire Plug in 20 kWh 85 km/h or > 208km range

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    Ho ! I think you will appreciate the attached file ;)
     

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    • bms2.zip
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  2. lopezjm2001

    lopezjm2001 Senior Member

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    Thats great. We can now start building some BMS2s.
    Thanks.
     
  3. miscrms

    miscrms Plug Envious Member

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    Very cool, thanks for saving these! Glad that Norm put them out there before closing up shop, but still sorry to hear he's done.
     
  4. elman1

    elman1 Junior Member

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    Do you know anyone who could manufacture a BMS+/2 ?

    I would be a buyer !
     
  5. lopezjm2001

    lopezjm2001 Senior Member

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    No, but you can do the following DIY:

    1. Download the zip file http://priuschat.com/attachments/bms2-zip.72472/
    The zip file contains four files as shown below:
    ZIP file content.png

    2. Download the free software from the website ExpressPCB - Free PCB layout software - Low cost circuit boards - Top quality PCB manufacturing, as shown below.

    Free software.png

    then install the programs ExpressPCB.exe and ExpressSCH.exe.

    3. Run the program ExpressPCB.exe and then open the file BMS2.pcb. It should look like below.

    ExpressPCB program..png

    4. Order the PCB online using the program ExpressPCB.exe . Select "LAYOUT" in the drop down menu. Then select "Order boards via internet..." as shown below. Just follow the prompts.
    ExpressPCB1.png

    5. Once you receive the PCB by mail you just need to order the list of electronic components from Digikey, they are listed in a file called BMS2basicparts.xls. As shown below.

    Digikey parts list.png

    6. Use some soldering skills to solder the electronic components onto the PCB. The finished PCB should look like below.

    [​IMG]

    7. Buy a metal box (included in parts list from DigiKey) to house the PCB. Then it should look like this:

    [​IMG]

    The grey plug inlet is for uploading the Hex code using the Silabs USB programmer.

    The black plug inlet is for a plug to wire into the Prius Canbus wires at the OEM battery ECU at the rear of the car next to the OEM battery. As shown in photo below. This plug also powers the BMS2.

    batteryECUplug.png


    The red 6 dip switches 1 and 2 are used to select which processor (BL or BR) to upload Hex code into BMS2.

    Switch 1 - BL Sw1 up and sw2 down to upload BL hex code.
    Switch 2 - BR Sw2 up and sw1 down to upload BR hex code.
    Switch 3 - P1 - Standalone end voltage 200-214v(J9 open) or 210v-224v(j9 closed).
    Switch 4 - P2 - Standalone end voltage 200-214v(J9 open) or 210v-224v(j9 closed).
    Switch 5 - P3 - Standalone end voltage 200-214v(J9 open) or 210v-224v(j9 closed).
    Switch 6 - P4 - OEM pack/Lithium pack, Up - Lithium (uses set end voltage) Down - OEM pack.

    j7, j8, j9 - jumper 7, jumper 8 and jumper 9 are located together at center of BMS2 PCB.

    J7-8.png


    [​IMG]

    Rear PCB connectios.png

    P1-3.png

    More detail of the rear terminal block can be found here blank

    The black round inlet is for a power plug from a DC power supply. It must have a DC power plug of type 2.1mm x 5.5mm, center positive, rated at anywhere between 8v to 18v, 100mA or higher. You will need this DC power supply to upload the Hex codes, should only be used when BMS2 is not connected to the Prius.

    8.Run the program called ExpressSCH.exe and then open the file BMS_harness.sch drawing to wire the BMS2 into the CANbus wiring. As shown below.

    BMS2Wiring.png

    Also see this http://priuschat.com/attachments/installation-of-a-bms2-pdf.74408/?temp_hash=54d602b27fa5965f148cee6f35341824

    9. Upload the HEX code (BL and BR) into the BMS2 (same as V4) as described here: CAN-view Downloads

    Need to buy a USB Programmer (US$40.32) from Digikey, part # 336-1182-ND to upload Hex code into BMS2. This will function on all newer laptops and desktops. They also have a free software program, UtilDLL.exe which you can download from their website: here

    Actual HEX code files are here: http://priuschat.com/attachments/bmsplus-bms2-codes-zip.72471

    For BMS2 use the two Hex code files BL2oct242.hex and BRapr029.hex


    BMS2 Codes.png

    10. Read the introduction to BMS2 here blank

    For more info read a archived copy of Norm's website before it closed down - CAN-view index
     

    Attached Files:

    #25 lopezjm2001, Jan 13, 2015
    Last edited: Jan 25, 2015
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  6. mrbigh

    mrbigh Prius Absolutum Dominium

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    Easy enough to have a brand new BMS2
     
  7. elman1

    elman1 Junior Member

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    what was your final cost for your homemade bms2 ?
    care to build me one ?

    ..open question to those who successfully followed instructions.
     
  8. mrbigh

    mrbigh Prius Absolutum Dominium

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    No, I never built one from scratch. I receive Production/test prototype number 1, a loooong time ago
     
  9. miscrms

    miscrms Plug Envious Member

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    Playing with the ExpressPCB software a bit, its estimating $106 shipped for 2 boards on their standard budget process (no silk sceen, no solder mask). On their protopro option, its estimating $180 for 4 boards shipped with the fancier (and perhaps easier to assemble) silk screen and solder mask steps.

    Rob
     
  10. elman1

    elman1 Junior Member

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    do they also offer assembling service, providing you send them parts list ?
     
  11. lopezjm2001

    lopezjm2001 Senior Member

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    No.
     
  12. lopezjm2001

    lopezjm2001 Senior Member

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    I calculated a price estimate of US$288 & delivery for doing this project as shown below:

    BMS2 DIY Price.png
     
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  13. whereswally606

    whereswally606 Junior Member

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    So I have really liked what planetaire did with his prius second gen.
    I looked into getting a bms+ which led me here and then I got annoyed that the original pcb files were stuck in proprietary expressPCB format.

    After a lot of tinkering I think i've managed to extract the bottom top and silk gerbers from them so that you can use your own preferred fabrication house which should be a lot cheaper or just make the boards yourself.

    I don't know however about the drill map so that's a potential issue

    this process I roughly followed was from another website but I can link so here is the content

    Open your ExpressPCB file and Print, selecting the new PS printer.

    I chose TOP and BOTTOM layer only.. it will ask you to name a the File.

    Now using CadLink 5; //(I used linkcad 9 trial)

    Import > POSTSCRIPT Export > Gerber RS-274-X
    NEXT
    select "Treat White areas as holes"
    NEXT
    under "Geometry Settings" I changed 0.001 to 0.02 default line width //didn't need to do this
    NEXT
    locate your PS print file and OK
    then complete the sequence of naming and saving.



    but used linkcad 9 trial to process from ps file to gerber format.

    There was a bit a tinkering needed to get a suitably aligned print from the original but this should now be more accessible to the home gamer crowd. I found the silkscreen objects contained the hole pads and this meant ungrouping and deleting silk object individually, expressPcb made it sufficiently tedious to reverse engineer their pcbs that I wont make a habit of it. Also the silk screen objects hanging of the left hand side of the board pushed the print out of alignment so I deleted any overhanging lines to fix that.

    my situation is that I own a Honda insight mk1 hybrid and my wife has a leaf, but we are about to have our second child and the insight being a 2 seater is not going to fulfil the remit of holiday/long journey family car. the Leaf is a 2011 jap import one but its not got amazing range so travelling the 200miles required is not going to be probably on the odd occasion its needed.

    If I can get a cheap 2nd hand 2nd gen prius and do what planetaire has done I will tick a lot of my required boxes.

    Please find attached the new gerbers. this are untested use them at your own risk.
     

    Attached Files:

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  14. bisco

    bisco cookie crumbler

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    welcome! please keep us posted on your progress, all the best!(y)
     
  15. whereswally606

    whereswally606 Junior Member

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    So I had a go at solving my drill file dilemma. I have something probably workable in that they are all in the right places, but I didn't manage to align the drill file with the pcb copper and silk layers. I'm hoping that the PCB fab shop can do this without much bother.

    Anyway a quick look on line shows 5 boards for $42 delivered. Hope somebody can make use of this. the other big cost in this project is that $35 hex flashing dongle.
     

    Attached Files:

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  16. Dxta

    Dxta Senior Member

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    Im sorry guys, for asking probably a "stupid" question.

    I wish someone can explain what this new bms2 does. Is it something that bypasses the stock BMS, and controls another battery installed on the vehicle?


    Thanks
     
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  17. whereswally606

    whereswally606 Junior Member

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    Not a stupid question and one I'm not sure I know the answer to but...

    I think it does what the bms+ did and then a bit more but I don't know what more and I'm only really bothered about the bms+ functionality to replicated what planetaire did on his 129mile ev only miles prius gen 2. I think the point for me is to allow the car to use more than the stock ah in the nimh battery that limits you to adding meaningful range with an auxiliary extra battery.

    In other news I found a brilliant program called gerbV, not to beconfused with gerbview, GerbV has allowed me to align the drill map gerber with the rest of the copper in the silk screen so I think I may now have a proper set of files to be able to send to a fabrication house of your choosing or role your own. But as always, this isn't tested, do your own checking before blaming me please.
     

    Attached Files:

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  18. whereswally606

    whereswally606 Junior Member

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    Lastly this is the fullset of gerbers with a solder mask layer top and bottom (which is the same). clearly there are only a couple of smt parts on the board so this should suffice. I've sent the design off to pcbway to see whether they will produce it and how much for. if anyone else is interested I should have 4 left to sell.
     

    Attached Files:

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  19. whereswally606

    whereswally606 Junior Member

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    good news, the pcb passed audit. If people are interested please message me. I only intend to cover my costs as I don't need 5 boards. Also I haven't bought the prius yet so I wont order the boards till I have 4 interested parties or when I buy the car (whichever comes first)
     
  20. lopezjm2001

    lopezjm2001 Senior Member

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    Sounds like a good deal. $8.40 each plus delivery? Shame I already have one. Thanks.
     
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