Toyota Prius, Plug-in Hybrid 2010, 2010 PRIUS, 2012 PRIUS User Manual

Plug-in Hybrid

2010 Model

Revised (includes 2012 Model)

Prius Plug-in hybrid ERG REV A – (02/22/12)

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oreword

This Prius Plug-in hybrid Emergency Response Guide has been revised to include the changes of the 2012 model year Prius Plug-in hybrid. These changes include minor updates to the vehicle exterior, interior and hybrid system. The important changes affecting the emergency responder are the reshaped high voltage battery assembly, HV battery voltage, and location of charge inlet door. While many features of the Prius Plug-in hybrid are shared with the 2010 3rd generation Prius hybrid, emergency responders should recognize and understand the new features of the Prius Plug-in hybrid covered in this guide.

High voltage electricity powers the electric motor, generator, air conditioning compressor and inverter/converter. All other automotive electrical devices such as the headlights, radio, and gauges are powered from a separate 12 Volt system. Numerous safeguards have been designed into the Prius Plug-in hybrid to help ensure the high voltage, approximately 346 *1/207.2 *2 Volt, Li-ion Hybrid Vehicle (HV) battery assembly is kept safe and secure in an accident.

*1: 2010 Model *2: 2012 Model

The 2010 Model Prius Plug-in hybrid utilizes the following electrical systems:

• Maximum 650 Volts AC

• Nominal 346 Volts DC

• Nominal 120/240 Volts AC

• Maximum 27 Volts DC

• Nominal 12 Volts DC

The 2012 Model Prius Plug-in hybrid utilizes the following electrical systems:

• Maximum 650 Volts AC

• Nominal 207.2 Volts DC

• Nominal 120/240 Volts AC

• Maximum 27 Volts DC

• Nominal 12 Volts DC

2010 Model Prius Plug-in hybrid features:

• An electric vehicle charge cable rated at 120 Volts.

• An onboard battery charger with a 120 Volt /240 Volt AC input and

346 Volt DC output.

• A boost converter in the inverter/converter that boosts the available

voltage to the electric motor to 650 Volts.

• A high voltage Hybrid Vehicle (HV) Li-ion battery assembly rated

at 346 Volts.

• A high voltage motor driven Air Conditioning (A/C) compressor

rated at 346 Volts and a heat pump type remote air conditioning system.

• A body electrical system rated at 12 Volts, negative chassis ground.

• Supplemental Restraint System (SRS) – dual stage frontal airbags,

front seat mounted side airbags, side curtain airbags, front seatbelt pretensioners, and driver knee airbag.

2012 Model Prius Plug-in hybrid features:

• An electric vehicle charge cable rated at 120 Volts.

• An onboard battery charger with a 120 Volt /240 Volt AC input and

207.2 Volt DC output.

• A boost converter in the inverter/converter that boosts the available

voltage to the electric motor to 650 Volts.

• A high voltage Hybrid Vehicle (HV) Li-ion battery assembly rated

at 207.2 Volts.

• A high voltage motor driven Air Conditioning (A/C) compressor

rated at 207.2 Volts and remote air conditioning system.

• A body electrical system rated at 12 Volts, negative chassis ground.

• Supplemental Restraint System (SRS) – dual stage frontal airbags,

front seat mounted side airbags, side curtain airbags, front seatbelt pretensioners, and driver knee airbag.

High voltage electrical safety remains an important factor in the emergency handling of the Prius Plug-in Hybrid Synergy Drive. It is important to recognize and understand the disabling procedures and warnings throughout the guide.

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Additional topics in the guide include:

The following indicates the key identification points for each model. Make sure to identify the target vehicle using this and refer to the corresponding rescue methods.

• Prius Plug-in hybrid identification.

•

Major Hybrid Synergy Drive component locations and descriptions.

•

Extrication, fire, recovery, and additional emergency response information.

Key Identification Points:

•

Roadside assistance information.

The main difference is that the charge inlet door has been relocated from the driver side front fender to the passenger side rear quarter panel.

2012 Model Year Prius Plug-in Hybrid 2010 Model Year Prius Plug-in Hybrid

Charge Inlet Door

2010 Model

This guide is intended to assist emergency responders in the safe handling of a Prius Plug-in hybrid vehicle during an incident.

NOTE:

Emergency Response Guides for Toyota hybrid and alternative fuel vehicles may be viewed at http://techinfo.toyota.com.

2012 Model

Charge Inlet Door

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Table of Contents (2010 Model) Page

About the Prius Plug-in Hybrid 1 Prius Plug-in Hybrid Identification 2 Hybrid Synergy Drive Component Locations & Descriptions 5 Plug-in Charging System Component Locations & Descriptions 8 Smart Key System 9 Electronic Gearshift Selector 11 Hybrid Synergy Drive Operation 12

Hybrid Vehicle (HV) Battery Assembly 13

Plug-in Charging System 14 Remote Air Conditioning System 16 Low Voltage Battery 18 High Voltage Safety 19 Plug-in Charging Safety 20 SRS Airbags & Seat Belt Pretensioners 22 Emergency Response 24 Extrication 24

Fire 31 Overhaul 32 Recovery of Li-ion HV Battery Assembly 32 Spills 33 First Aid 33 Submersion 34

Table of Contents (2010 Model) Page

Roadside Assistance 35

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Table of Contents (2012 Model) Page

About the Prius Plug-in Hybrid 39 Prius Plug-in Hybrid Identification 40 Hybrid Synergy Drive Component Locations & Descriptions 43 Plug-in Charging System Component Locations & Descriptions 46 Smart Key System 47 Electronic Gearshift Selector 49 Hybrid Synergy Drive Operation 50

Hybrid Vehicle (HV) Battery Assembly 51

Plug-in Charging System 52 Remote Air Conditioning System 54 Low Voltage Battery 55 High Voltage Safety 56 Plug-in Charging Safety 57 SRS Airbags & Seat Belt Pretensioners 59 Emergency Response 61 Extrication 61

Fire 68 Overhaul 69 Recovery of Li-ion HV Battery Assembly 69 Spills 70 First Aid 70 Submersion 71

Table of Contents (2012 Model) Page

Roadside Assistance 72

About the Prius Plug-in Hybrid (2010 Model)

The Prius Plug-in hybrid contains a gasoline engine, an electric motor, and a newly developed large capacity Li-ion battery. It is the first Toyota hybrid that allows the HV battery to be plugged-in and charged by an external power source. Two power sources are stored on board the vehicle:

When the HV battery is discharged the vehicle operates in Hybrid Vehicle mode

1. Gasoline stored in the fuel tank for the gasoline engine.

2. Electricity stored in a large capacity externally chargeable high voltage Hybrid Vehicle (HV) battery assembly for the electric motor.

HV (Hybrid Vehicle) Mode:

 During light acceleration at low speeds, the vehicle is powered by

the electric motor. The gasoline engine is shut off.

Depending on the driving conditions, one or both sources are used to power the vehicle. The following illustration demonstrates how the Prius Plug-in hybrid operates in various driving modes.



During normal driving, the vehicle is powered mainly by the gasoline engine. The gasoline engine also powers the generator to recharge the HV battery assembly and to drive the electric motor.

Plug-in EV (Electric Vehicle) Mode:



During full acceleration, such as climbing a hill, both the gasoline engine and the electric motor power the vehicle.

 Utilizing the charge cable assembly connected to a 120 Volt outlet,

the vehicle’s HV battery can be charged within 3 hours.



During deceleration, such as when braking, the vehicle regenerates the kinetic energy from the front wheels to produce electricity that recharges the HV battery assembly.



When the HV battery is sufficiently charged, the vehicle will basically run on the power of the electric motor for approximately 13 miles.



While the vehicle is stopped, the gasoline engine and electric motor are off, however the vehicle remains on and operational.



If the vehicle exceeds approximately 60 mph (100 km/h) or accelerates suddenly when traveling in plug-in EV mode, the gasoline engine and electric motor work together to power the vehicle.

 Normal Driving

Plug-in charging

Electricity Electricity and gasoline Electricity and gasoline Electricity

Electricity and gasoline (Additional electricity extracted from batteries)

Charging batteries

Engine automatically stopped

 Hard Acceleration

 Starting  Normal Driving  Acceleration  Deceleration  Stopping  Plug-in Charging

Exceeds Approximately 60 mph (100 km/h)

Plug-in EV Mode HV (Hybrid Vehicle) Mode

Prius Plug-in Hybrid Identification (2010 Model) Prius Plug-in Hybrid Identification (2010 Model)

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In appearance, the 2010 model year Prius Plug-in hybrid is a 5-door hatchback. Exterior, interior, and engine compartment illustrations are provided to assist in identification.

The alphanumeric 17 character Vehicle Identification Number (VIN) is provided in the front windshield cowl and on the driver door pillar.

Example VIN: JTDKN3DPExample VIN: JTDKN3DPA82020211

A Prius Plug-in hybrid is identified by the first 8 alphanumeric characters JTDKN3DP.

Driver Side Windshield and Driver Side B Pillar

Exterior

 and logos on the hatch.  logo on the passenger side front fender.

 Charge inlet door with logo, located on the driver side front

fender.

 Plug-in Hybrid decals located on the sides of the vehicle.

Exterior Driver Side View

Exterior Front and Rear View

Exterior Rear and Driver Side View















Prius Plug-in Hybrid Identification (2010 Model Continued)

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Interior

Interior View

Instrument Cluster View



An instrument cluster (speedometer, READY light, shift position indicators,

warning lights) located in center of the dash and near the base of the windshield.

 A plug-in charge indicator light located on the upper dash near the driver

side windshield.







Prius Plug-in Hybrid Identification (2010 Model Continued)

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Engine CompartmentEngine Compartment

Engine Compartment View



1.8-liter aluminum alloy gasoline engine.

 Logo on the plastic engine cover.



Hybrid Synergy Drive Component Locations & Descriptions (2010 Model)

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Component Location Description

12 Volt  Auxiliary Battery

Passenger Side of Cargo Area

A lead-acid battery that supplies power to the

low voltage devices. Hybrid  Vehicle (HV) Battery Assembly

Cargo Area 346 Volt Lithium-ion (Li-ion) battery pack

consisting of 3.6 Volt cells connected in a

series-parallel circuit. Power  Cables Undercarriage

and Engine Compartment

Orange colored power cables carry high

voltage Direct Current (DC) between the HV

battery assembly, inverter/converter, and A/C

compressor. These cables also carry 3-phase

Alternating Current (AC) between the

inverter/converter, electric motor, and

generator. Inverter/ Converter 

Engine Compartment

Boosts and inverts the high voltage electricity

from the HV battery assembly to 3-phase AC

electricity that drives the electric motor. The

inverter/converter also converts AC

electricity from the electric generator and

electric motor (regenerative braking) to DC

that charges the HV battery assembly. Gasoline  Engine

Engine Compartment

Provides two functions:

1) Powers vehicle.

2) Powers generator to charge the HV battery

assembly.

The engine is started and stopped under

control of the vehicle computer. Electric  Motor

Engine Compartment

3-phase high voltage AC motor contained in

the front transaxle. It is used to power the

front wheels. Electric  Generator

Engine Compartment

3-phase high voltage AC generator that is

contained in the transaxle and charges the

HV battery assembly. A/C Compressor (with Inverter) 

Engine Compartment

3-phase high voltage AC electrically driven

motor compressor.

Hybrid Synergy Drive Components















Components (Top View) and High Voltage Power Cables

















Hybrid Synergy Drive Component Locations & Descriptions (2010 Model - Continued)

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Component Location Description

Fuel Tank and Fuel Line



Undercarriage and Center

The fuel tank provides gasoline via a fuel

line to the engine. The fuel line is routed

under the center of vehicle.

Fuel Tank and Fuel Line



Hybrid Synergy Drive Component Locations & Descriptions (2010 Model - Continued)

Key Specifications:Key Specifications:

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Gasoline Engine: 98 hp (73 kW), 1.8-liter Aluminum Alloy Engine

Electric Motor: 80 hp (60 kW), AC Motor

Transmission: Automatic Only (electrically controlled

continuously variable transaxle)

HV Battery Assembly: 346 Volt Sealed Li-ion

Battery

Curb Weight: 3,362 lbs/1,525 kg

Fuel Tank: 10.6 gals/40.0 liters

Frame Material: Steel Unibody

Body Material: Steel Panels except for Aluminum Hood and

Hatch

Seating Capacity: 5 passenger

Steel Unibody

Aluminum Hood

Aluminum Hatch

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lug-in Charging System Component Locations &

Descriptions (2010 Model)

Component Location Description

Charge Inlet  Driver Side Front

Fender

Connects to the charge cable assembly

charge connector. Supplies the electrical

power from an external power source to the

vehicle.

Power Cable for Charging 

Driver Side behind front fender

Power cable connecting the charge inlet and

charger assembly.

Charger Assembly 

Under Front Passenger Seat

Boosts the AC power supplied from an

external power source and converts it to DC

to charge the HV battery assembly and

operate the A/C compressor.

Charge Cable Assembly 

Driver Side Front Fender

Connects to the charge inlet and supplies

power from an external power source to the

vehicle.

Charge Indicator 

Upper Dash near Driver Side Windshield

Illuminates, flashes, or goes off to indicate

the plug-in charging status. Also

illuminates to indicate the operation of the

remote air conditioning system.

Plug-in Charging System Components

Components (Top View) and Charge Inlet Power Cables















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mart Key System (2010 Model)

The Prius Plug-in hybrid smart key system consists of a smart key transceiver that communicates bi-directionally, enabling the vehicle to recognize the smart key in proximity to the vehicle. Once recognized, the smart key will allow the user to lock and unlock the doors without pushing smart key buttons, and start the vehicle without inserting it into an ignition switch.

Smart key features:

•

Passive (remote) function to lock/unlock the doors and start the vehicle.

•

Wireless transmitter buttons to lock/unlock all 5 doors.

•

Hidden metal cut key to lock/unlock the doors.

Door (Lock/Unlock)

There are several methods available to lock/unlock the doors.

• Pushing the smart key lock button will lock all doors including the hatch. Pushing the smart key unlock button once unlocks the driver door, twice unlocks all doors.

• Touching the sensor on the backside of the driver door exterior handle, with the smart key in proximity to the vehicle, unlocks the driver door. Touching the sensor on the backside of the front passenger door exterior handle, with the smart key in proximity to the vehicle, unlocks all doors. Touching the lock sensor on either front door, or the lock button for the hatch will lock all doors.

• Inserting the hidden metal cut key in the driver door lock and turning clockwise once unlocks the driver door, twice unlocks all doors. To lock all doors turn the key counter clockwise once. Only the driver door contains an exterior door lock for the metal cut key.

Smart Key (Fob) Hidden Metal Cut Key for Door Lock

Driver Door Unlock Touch Sensor and

Lock Touch Sensor

Front Driver Door Lock

Hatch Lock Button

Release Button

Unlock Touch Sensor

Use the Hidden Metal Cut Key

Lock Touch Sensor

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mart Key System (2010 Model - Continued)

Vehicle Starting/Stopping

The smart key has replaced the conventional metal cut key, and the power button with an integral status indicator light has replaced the ignition switch. The smart key only needs to be in proximity to the vehicle to allow the system to function.

• With the brake pedal released, the first push of the power button operates the accessory mode, the second push operates the ignition-on mode, and the third push turns the ignition off again.

Ignition Mode Sequence (brake pedal released):

• Starting the vehicle takes priority over all other ignition modes and is accomplished by depressing the brake pedal and pushing the power button once. To verify the vehicle has started, check that the power button status indicator light is off and the READY light is illuminated in the instrument cluster.

• If the internal smart key battery is dead, use the following method to start the vehicle.

1. Touch the Toyota emblem side of the smart key to the power button.

2. Within the 5 seconds after the buzzer sounds, push the power button

with the brake pedal depressed (the READY light will illuminate).

• Once the vehicle has started and is on and operational (READY-ON), the vehicle is shut off by bringing the vehicle to a complete stop and then depressing the power button once.

• To shut off the vehicle before coming to a stop in an emergency, push and hold down the power button for more than 3 seconds. This procedure may be useful such as at an accident scene in which the READY indicator is on and the drive wheels remain in motion.

Ignition Mode

Power Button Indicator Light

Off Off

Accessory Amber

Ignition-On Amber

Brake Pedal Depressed Green

Vehicle Started (READY-ON) Off

Malfunction Blinking Amber

Power Button with Integral Status

Indicator Light

Ignition Modes (Brake Pedal Released)

Starting Sequence

(Brake Pedal Depressed)

Smart Key Recognition

(When Smart Key Battery is Dead)

Accessory

Ignition-On

Vehicle Of

Button Push

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Electronic Shift Selector (2010 Model)

The Prius Plug-in hybrid electronic shift selector is a momentary select shift-by-wire system that can be used to select reverse (R), neutral (N), drive (D), or engine brake (B) states.

• These states may only be selected while the vehicle is on and operational (READY-on), except for neutral (N) which may also be selected while in the ignition-on mode. After R, N, D, or B is selected, the transaxle remains in that state, identified on the instrument cluster, but the shift selector returns to the home position. To select neutral (N), it is necessary to hold the shift selector in the N position for approximately 0.5 seconds.

• Unlike a conventional vehicle, the electronic shift selector does not contain a park (P) position. Instead, a separate P position switch located above the shift selector selects park (P).

• When the vehicle is stopped, regardless of shift state, the electromechanical parking lock pawl is engaged to lock the transaxle into park (P) by either pressing the P position switch or pressing the power button to shut off the vehicle.

• Being electronic, the shift selector and park (P) systems depend on the low voltage 12 Volt auxiliary battery for power. If the 12 Volt auxiliary battery is discharged or disconnected, the vehicle cannot be started and cannot be shifted into or out of park (P). There is no manual override except to reconnect the auxiliary battery or jump start the vehicle, refer to Jump Starting on page 38.

Electronic Shift Selector and P Position Switch

Home Position

Instrument Cluster Shift State Indicator

Indicates Gear Positio

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ybrid Synergy Drive Operation (2010 Model)

Once the READY indicator is illuminated in the instrument cluster, the vehicle may be driven. However, the gasoline engine does not idle like a typical automobile and will start and stop automatically. It is important to recognize and understand the READY indicator provided in the instrument cluster. When lit, it informs the driver that the vehicle is on and operational even though the gasoline engine may be off and the engine compartment is silent.

Vehicle Operation

• With the Prius Plug-in hybrid, the gasoline engine may stop and start at any time while the READY indicator is on.

• Never assume that the vehicle is shut off just because the engine is off. Always look for the READY indicator status. The vehicle is shut off when the READY indicator and instrument cluster lights are off.

• The vehicle may be powered by:

1. The electric motor only.

2. A combination of both the electric motor and the gasoline engine.

• The vehicle computer determines the mode in which the vehicle operates in order to improve fuel economy and reduce emissions. The Prius Plug-in hybrid features plug-in EV (Electric Vehicle) mode, a mode that is automatically selected when the HV battery is charged using an external power source. Power and ECO (Economy) modes are driver selectable.

1. ECO Mode: When activated, this mode helps enhance fuel economy on trips that involve frequent braking and acceleration.

2. Power Mode: Optimizes acceleration feel by increasing the power output more quickly at the beginning of accelerator pedal operation.

Instrument Cluster READY Indicator

Economy Drive Mode Switch/Power Mode Switch

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ybrid Vehicle (HV) Battery Assembly (2010 Model)

The Prius Plug-in hybrid features a large capacity high voltage Hybrid Vehicle (HV) battery assembly that contains newly developed sealed Lithium-ion (Li-ion) battery cells.

HV Battery Assembly

• The HV battery assembly is enclosed in a metal case and is rigidly mounted in the lower part of the cargo area behind the rear seat. The metal case is isolated from high voltage and concealed by a carpeted panel in the cabin area.

• The HV battery assembly consists of 3.6 Volt Li-ion battery cells connected in series-parallel circuit to produce approximately 346 Volts. Each Li-ion battery cell is non-spillable and contained in a sealed metal case.

• The electrolyte used in the Li-ion battery cells is a flammable organic electrolyte. The electrolyte is absorbed into the battery cell separator and will not normally leak, even in a collision.

Components Powered by the HV Battery Assembly

HV Battery Assembly Recovery

• If recovery of the HV battery assembly is necessary, please contact:

United States: (800) 331-4331 Canada: (888) TOYOTA 8 [(888) 869-6828]

HV Battery Assembly

Battery assembly voltage

346 V

Number of Li-ion battery cells in the battery

96 cells

Li-ion battery cell voltage

3.6 V

Li-ion battery cell dimensions

4.42 x 4.35 x 0.56 in.

(112.2 x 110.6 x 14.1 mm)

Li-ion cell weight

0.54 lbs (245 g)

Li-ion battery assembly dimensions

32.4 x 38.1 x 14.9 in.

(822.4 x 967.8 x 378.4 mm)

Li-ion battery assembly weight

333 lbs (151.1 kg)

•

Electric Motor

•

Inverter/Converter

• Power Cables • A/C Compressor

• Electric Generator

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ug-in Charging System (2010 Model)

The plug-in charging system uses an on-board charger to convert AC power supplied via the charge cable assembly to DC power that can be used to charge the HV battery assembly. The charging system uses refined charging control to ensure battery durability and prevent fires due to overcharging.

The utility power supplied by the charge cable assembly is converted by the onboard charger assembly to the approximately 346 Volts DC used to charge the HV battery assembly.

Prius Plug-in hybrid vehicles for North America are supplied with a charge cable assembly designed to allow charging from a 120 Volt AC NEMA 5-15R receptacle. The maximum current flow during charging is 12 A.

NOTE: The Prius Plug-in hybrid is compatible with aftermarket chargers or Electric Vehicle Supply Equipment (EVSE) available from different manufacturers other than Toyota. Some EVSE’s are available with 240 Volt input for quicker charging.

Safety Concerns Since the operation of the plug-in charging system allows high voltage electrical flow when the vehicle is shut off, it is important to recognize how the system is activated, deactivated, and disabled.

System Activation: The following steps provide a simplified explanation on how to charge the vehicle.

1. Confirm that the vehicle is off and in park (P).

2. Connect the charge cable assembly to a suitable 120 Volt wall receptacle.

3. Confirm the presence of power, and test the CCID (Charging Circuit Interrupter Device).

4. Connect the charge cable assembly to the vehicle charge inlet connector.

5. Confirm that the vehicle’s charge indicator illuminates.

When charging, the high voltage cables are energized. Utility electricity flows from the charge inlet, its voltage is then boosted and it is provided to the HV battery assembly and air conditioning compressor. Charging normally completes within 3 hours and will stop automatically.

Charge Cable Assembly and Charge

Indicator

CHARGE Indicator, TEST Button

and RESET Button

Plug-in Charging System Operation (READY Indicator Off)

Charge Indicator

DC Flow (Charger to Battery)

AC Flow (Inlet to Charger)

HV Battery Assembly

Charge Inlet

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Plug-in Charging System (2010 Model - Continued)

System Deactivation: The following steps explain how to stop charging.

1. Disconnect the charge cable assembly connector from the vehicle. To disconnect it, push the orange lock release button on the top of the connector and pull it away from the vehicle.

2. Close the charge inlet cap and charge inlet door.

3. Disconnect the plug of the charge cable assembly from the electrical outlet.

Disconnect Charge Cable Connector

Close Charge Inlet Cap and Charge

Inlet Door

Disconnect Plug Remove Battery Cover

Remove Tire Repair Kit and Foam Insert

When the charging system is deactivated, high voltage cables are deenergized and the high voltage electrical flow stops in the charge cable assembly and vehicle.

WARNING:

The high voltage system, including the charging system, may remain powered for up to 10 minutes after the vehicle is shut off, disabled, or charging stops. To prevent serious injury or death from severe burns or electric shock, avoid touching, cutting, or breaching any orange high voltage power cable or high voltage component.

System Disabling: To disable the charging system, disconnect the 12 Volt auxiliary battery after performing the above deactivation procedure.

12 Volt Auxiliary Battery

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Remote Air Conditioning System (2010 Model)

The following points can be used to confirm that the remote air conditioning system is operating:

The remote air conditioning system is provided to enhance occupant comfort by heating or cooling the vehicle interior while the vehicle is shut off and the charge cable assembly is plugged in.

The remote air conditioning system is similar to a remote engine start system used in a conventional gasoline vehicle to precondition the vehicle interior while the vehicle is parked. Unlike a conventional gasoline vehicle, the Prius Plug-in hybrid does not start the gasoline engine. Instead, to heat or cool the vehicle interior, it utilizes power from the charge cable assembly to operate the high voltage air conditioning compressor. The compressor operates in a conventional manner for cooling, and it operates as a heat pump for heating. The system can only be activated remotely by pushing the smart key A/C button and will operate for up to 30 minutes when certain conditions are met.

Safety Concerns Since the operation of the remote air conditioning system allows high voltage electrical flow, it is important to recognize how the system is activated, deactivated, and disabled.

System Activation: When the remote air conditioning system is activated, the high voltage cables are energized. Household electricity flows from the charge inlet, its voltage is then boosted and it is provided to the HV battery assembly and air conditioning compressor. The system can operate when all of the following operating conditions are met:

• The charge cable assembly is connected.

• The doors and hood are closed.

• The vehicle Power switch is off.

• The brake pedal is not being depressed.

• The shift position is park (P).

• The charge level of the HV battery assembly is above a specified level.

• There is a difference between the set temperature and actual cabin

temperature.

• Air is flowing from the interior vehicle vents, and blower fan noise or compressor noise is heard.

• The charge cable assembly is connected and the charge indicator is illuminated.

• The instrument cluster lights are on, the READY indicator is off, and all of the conditions in the preceding list are met.

Charge Indicator

Charge Cable Assembly and Charge

Indicator

Remote Air Conditioning System A/C

Button

Remote Air Conditioning System Operation (READY Indicator Off)

A/C Button

Charge Cable Assembly

12 Volt Auxiliary

Battery

Air Conditioning

Compressor

Charger Assembly

DC Flow

AC Flow

HV Battery Assembly

Charge Inlet

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Remote Air Conditioning System (2010 Model -Continued)

System Deactivation: When the system is deactivated, the A/C system stops. The system is deactivated when any one of the following conditions occurs:

• When the system has operated for more than about 30 minutes.

• When the vehicle interior nears the set temperature.

• When a door is opened, the hood is opened, or the brake pedal is

depressed.

• When the smart key A/C button is pushed twice within 3 seconds.

• When the operating conditions are not met.

NOTE:

• It is not possible to operate the remote A/C system and perform plug in charging of the HV battery assembly at the same time. If plug in charging is being performed and the remote A/C system is turned on, plug in charging will stop.

• Plug in charging will not resume after the remote A/C system deactivates.

WARNING:

The high voltage system, including the charging system, may remain powered for up to 10 minutes after the vehicle is shut off, disabled, charging stops, or the remote A/C system stops. To prevent serious injury or death from severe burns or electric shock, avoid touching, cutting, or breaching any orange high voltage power cable or high voltage component.

System Disabling: Operation of the remote air conditioning system can be disabled by disconnecting the charge cable assembly (see page 15 for illustration). Perform the following steps to remove the charge cable assembly.

1. Disconnect the charge cable assembly connector from the vehicle. To disconnect it, push the orange lock release button on the top of the connector and pull it away from the vehicle.

2. Close the charge inlet cap and charge inlet door.

3. Disconnect the plug of the charge cable assembly from the electrical outlet.

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Low Voltage Battery (2010 Model)

Auxiliary Battery

• The Prius Plug-in hybrid contains a sealed lead-acid 12 Volt battery. The 12 Volt auxiliary battery powers the vehicle’s electrical system similar to a conventional vehicle. As with conventional vehicles, the negative terminal of the auxiliary battery is grounded to the metal chassis of the vehicle.

• The auxiliary battery is located in the cargo area. It is concealed by a fabric cover, tire repair kit, and foam insert on the passenger side in the rear quarter panel well.

NOTE: An under hood label shows the location of the HV battery assembly (traction battery) and 12 Volt auxiliary battery.

Remove Auxiliary Battery Cover

Remove Tire Repair Kit and Foam

Insert

Battery Location Label

12 Volt Auxiliary Battery

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igh Voltage Safety (2010 Model)

The HV battery assembly powers the high voltage electrical system with DC electricity. Positive and negative orange colored high voltage power cables are routed from the HV battery assembly, under the vehicle floor pan, to the inverter/converter. The inverter/converter contains a circuit that boosts the HV battery voltage from 346 to 650 Volts DC. The inverter/converter creates 3phase AC to power the motor. Power cables are routed from the inverter/converter to each high voltage motor (electric motor, electric generator, and A/C compressor). The following systems are intended to help keep occupants in the vehicle and emergency responders safe from high voltage electricity:

High Voltage Safety System

• High voltage fuses  provide short circuit protection in the HV battery assembly.

• Positive and negative high voltage power cables  connected to the HV battery assembly are controlled by 12 Volt normally open relays . When the vehicle is shut off and not charging, the relays stop electrical flow from leaving the HV battery assembly.

WARNING:

• Both positive and negative power cables  are insulated from the metal body. High voltage electricity flows through these cables and not through the metal vehicle body. The metal vehicle body is safe to touch because it is insulated from the high voltage components.

• A ground fault monitor  continuously monitors for high voltage leakage to the metal chassis while the vehicle is running. If a malfunction is detected, the hybrid vehicle computer  will illuminate the master warning

light

in the instrument cluster and indicate “Check Hybrid System” on

the multi-information display.

High Voltage Safety System – Vehicle Shut Off (READY-OFF)

High Voltage Safety System – Vehicle On and Operational (READY-ON)

Hybrid Vehicle Computer



Volt DC

12 Volt Auxiliary Battery



A/C Compressor



Electric Generator

Inverter/



Converter

Electric Motor

Volt DC



Volt AC Volt DC

3-Phase



Battery Charger Assembly

HV Battery Assembly

Hybrid Vehicle Computer

346

Volt DC

12 Volt Auxiliary Battery

A/C Compressor

Electric Generator

Inverter/ Converter

HV Battery Assembly

AC 3-Phase

Electric Moto

Volt DC

346

Volt AC

Volt DC

Battery Charger Assembly

3-Phase

+ 56 hidden pages

Toyota Prius, Plug-in Hybrid 2010, 2010 PRIUS, 2012 PRIUS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual