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Prius PHEV Schematics

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Contents

This is where you will find schematics, PCB layout, and parts lists for various Prius PHEV conversions.

[edit] Original CalCars Method

Further development of the PriusPlus History or Prius PHEV#Original CalCars Method has been postponed to persue the Prius PHEV#Hybrid-Pack Method so the original schematics can be found at Prius PHEV Schematics-CalCars

[edit] Hybrid-Pack Method

There is no longer a need for the Battery Tap Emulator when using a hybrid battery pack configuration. The HV interface with the original OEM battery is made after the HAL (current) sensor. If the OEM BMS does not measure enough current leaving the OEM battery it will shut down the OEM HV systems within about 1 mile or a few minutes. The OEM BMS does not however appear to mind to much current leaving the OEM battery, thus it may be possible to draw large amounts of power out of the OEM battery through the HAL sensor for a sort of "Genset Mode" of operation. These HV taps between the OEM and add on PHEV Battery Pack are common between the Contactor and PFC based conversions.

View with fixed-width fonts
                       |======[? (-) for Genset Mode ?]
                       |
=(-)=[=#=OEM_Contactor=#=]===[|]==#========(-)
                             HAL  |      [_OEM_Battery_]
To HSD                    SENSOR  |    |===(+)
                                  |    | 
=(+)=[=#=OEM_Contactor=#=]========|====| 
                       |          |      
                       |====|     |      
                            |     |      
(     # interconnect )     (+)   (-)     
( = & | 6 guage wire )  [_PHEV_Battery_]

[edit] Contactor Based

See the PriusPlus article for schematics, documentation, and other resources for the Contactor Based PriusPlus Mothod.

[edit] PFC Based

No new Schematics for these methods yet, Only ASCII Art...

[edit] Manual Anderson Quick Mode Change.

This was used for early testing before the relay box was designed and produced.

View with fixed-width fonts
Manual Anderson Quick Mode Change.
( 6 red, 6 black )
 _______________ _ _____________________               
 In   PFC AC(+) \ / (+) 110/220AC   CHG |              
 _____PFC_AC(-)_/_\_(-)____________ CHG______          
 Out  PFC DC(+) \ / (+) PbA (PHEV)  CHG PHEV |         
 _____PFC_DC(-)_/_\_(-)________________ PHEV_____      
                  / (+) NiMH (OEM)      PHEV RGN |     
 _ _ _ _ _ _ _ _ _\_(-)____________ _ _ _____RGN |     
                  / (+) PbA (PHEV)           RGN |     
 _ _ _ _ _ _ _ _ _\_(-)____________ _ _ _ _ _____|     

                 _ ________________                    
  "Special Mode"  / (+) HSD (? HAL sensor ?)           
  Wayland at the _\_(-)____________                    
  track charging  / (+) DC Output (! NEDRA !)          
  Genset Mode ?? _\_(-)____________                    
--Rjf 00:40, 26 May 2006

[edit] Automatic Charge - PHEV Drive Mode Change (No Regen)

 View with fixed-width fonts
 This has not yet been validated for proper operation, and may not have ever been implemented.
 Automatic [ Charge - PHEV Drive ] Mode Change, HV & LV Layout
 coil 01 is a pair of DPDT or a single 4PDT
 coil 02 is a SPST (Rated 40+ Amps for DC MAKE/BREAK)
   * Ignition energizes mode change (unless PFC is running from grid)
   * CAN-View RL4 (OEM/PHEV Mode) energizes Coil 02 powering up PFC (DC MAKE)
   * Once PFC is running mode change is energized by both ignition and PFC RegBus
   ** Ignition off results in CAN-View RL4 releasing powering down PFC (DC BREAK)
   ** Mode change can only return to grid once PFC RegBus goes offline

      (+)[Grid](-)      (+)[PbA](-)        (-)[NiMH](+)
       |        |        |       |          |        |
       |   |====|========#=======|==========|====|   |
       |   |    |                |          |    |   |
       |   |    |   |=======|    #======|   |    |   |
       |   |    |   |     __|____|__    |   |    |   |
       |   |    |   |     | # ,, # !    |   |    |   |
     __|___|____|___|__   !  ----  !  __|___|____|___|__
     ! #   #    #   # !   !  %%%%  !  ! #   #    #   # !
     !  \ , %%%% \ ,  !   !  coil  !  !  \ , %%%% \ ,  !
     !   \  coil  \   !   !___02___!  !   \  coil  \   !
     !___#___01___#___!               !___#___01___#___!
         |        |   \               /   |        |
         |(+)  (-)|    \             /    |(-)  (+)|   ( +5v from   )
        [PFC Input]     \           /    [PFC Output]  ( PFC RegBus )
                         \<===#===>/                    | |
                              |                         | |  (Ign +12v)---<
  |=====|    |=====#==========|====================|    | |    |
  |   __|____|__   |          |                    |    | |    |
  |   | # ,, # !   |   (coil / 01)   |========|    |    | |    |    |=====|
  |   !  ----  !   |  ______|________|__    __|____|__  | |  __|____|__   |
  |  g===%%%%====| |  ! #   #    #   # !    | # ,, # !  | |  | #____# !   |
  |   !   NO   ! | |====%\ ,%%%%%%\ ,%==g   !  ----  !  | |  !  ....  !   |
  |   !________! |    !   \        \   !  |====%%%%=====#=|=====%%%%====| |
  |              |    !___#________#___!  | !   NO   !    |  !   NC   ! | |
  |              |        |        |      | !________!    |  !________! | |
  |===(Bat +12)==|========#========#      |===============#=============| |
          |      |                                                        |
          ^      |========================================================|
 --Rjf 06:51, 2 September 2006 (CDT)


[edit] Automatic Charge - PHEV Drive Mode Change (With Regen)

 View with fixed-width fonts
 This has not yet been validated for proper operation, and may not have ever been implemented.
 Automatic [ Charge - PHEV Drive - Regen ] Mode Change, HV Layout
 Pair of DPDT or 4PDT, DPDT, and SPST (40+ Amps, 12v coils)
    (+)[Grid](-)                 Inputs --> State|Machine --> Outputs
   __|________|__  +12v-|->(CAN RL3, NO, RGN )-->|-->(Execute Regen mode Procedure below)
   ! |coil 05 | !  Key  |->(CAN RL2, NO, SOC )-->|-->(PFV V set NiMH high)
   ! |AC rated| !       |->(CAN RL4, NO, PHEV)-->|-->(coil 04)
   !_|________|_!  |-NC->(Key On, +12v, Brown)-->|-->(Interlock, coil 01 & 02, PFC V set NiMH low)
     |        |    |             |-NC----------->|-->(Open OEM HV+ Contactor ground control, Black)
    (|AC sense|)---|-------------|----110vac---->|-->(PFC Current <15Amps)
     |        |
     |   |====|======================================|
     |   |    |                                      |
     |   |    |   |==================================|========|
   __|___|____|___|__                                |        |
   ! #   #    #   # !                                |        |
   !  \ , %%%% \ ,  !                                |        |
   !   \  coil  \   !   (+)[PbA](-)        (-)[NiMH](+)[NiMH](-)Regen Mode?
   !___#___03___#___!    |       |          |        |  Inverter side of OEM contactor
       |        |        |       |          |        |
       |   |====|========#=======|==========|====|   |
       |   |    |                |          |    |   |
       |   |    |   |=======|    #======|   |    |   |
       |   |    |   |     __|____|__    |   |    |   |
       |   |    |   |     | # ,, # !    |   |    |   |
     __|___|____|___|__   !  ----  !  __|___|____|___|__
     ! #   #    #   # !   !  %%%%  !  ! #   #    #   # !
     !  \ , %%%% \ ,  !   !  coil  !  !  \ , %%%% \ ,  !
     !   \  coil  \   !   !___04___!  !   \  coil  \   !
     !___#___01___#___!               !___#___02___#___!
         |        |                       |        |
         |(+)  (-)|                       |(-)  (+)|
        [PFC Input]                      [PFC Output]
 --Rjf 15:49, 14 June 2006 (CDT)

 View with fixed-width fonts
 This has not yet been validated for proper operation, and may not have ever been implemented.
 coils     Can we get a four poll triple throw 40A, 60A, or 120A Contactor or Drum Switch? 
 12345
 ----- Charge Mode
 00000 - Grid -> PbA, (PFC V set PbA default)
 ////0 - 110v AC Present (DC immune) coil 01-04, Key On, and RLx interlock. (Set PFC Current < 15A)
 ////0 - 220v AC Present (DC immune) coil 01-04, Key On, and RLx interlock. (Leave PFC Current Full)
       - Key On Interlock opens a NC relay which grounds the (+)pos OEM Contactor.
       - Run Interlock opens a NC relay which would otherwise go (+12) upon Key On.
       - Open a NC relay which provides coil 01-04 & CAN RLx grounds, disabling all.
 ----- Power up sequence Key On
 00000 - Key Off, ready to but not charging state
 00001 - open coil 05 (NC), ac interlock
 01001 - coil 02 Output -> NiMH, PFC V set NiMH low
 11001 - coil 01 Input -> PbA
         CAN-View "PHEV" Mode, Relay RL4^
 11011 - Close coil 04 (NO), Connect PbA (-)neg leg (PFC On)
         CAN-View ?RL2^? (SOC/CCL Driven)
 11011 - PFC V set NiMH high
 ----- Power down sequence Key Off
 11011 - Key On, and PHEV run state
 11001 - Open coil 04 (NO), Disconnect PbA (-)neg leg (PFC Off)
 01001 - coil 01 Input -> Grid
 00001 - coil 02 Output -> PbA, PFC V Set PbA
 00000 - close coil 05 (NC), ac interlock
 ----- CAN-View ?RL3^? (Enter Regen Mode)
     1 - only while grid interlock is active
 11011 - Key On, and PHEV run state
         Do Power down sequence Emulate Key Off less last state
 11001 - Open coil 04 (NO), Disconnect PbA (-)neg leg (PFC Off)
 01001 - coil 01 Input -> Grid
 00001 - coil 02 Output -> PbA, PFC V Set PbA
 00101 - coil 03 NiMH(Regen) -> Grid Input (PFC On)
 ----- CAN-View ?RL3v? (Exit Regen Mode)
 00101 - Key On, and PHEV regen state
 00001 - coil 03 Grid -> Grid Input (PFC Off)
 01001 - coil 02 Output -> NiMH, PFC V Set NiMH low
 11001 - coil 01 Input -> PbA
 11011 - Close coil 04 (NO), Connect PbA (-)neg leg (PFC On)
 ----- Other Notes
 01001 - coil 02 & 01 states may be safe to combined
 11001 - coil 01 & 02 states may be safe to combined
 Forced PbA Charge Mode
 (One could manually enter forced PbA charge mode by safely engaging stationary regen ?RL3^?)
 Further, External Charging by:
 (Shut off PFC, hyjack PFC output via Andersons, V tune (?independent?) and charge)
 --Rjf 15:49, 14 June 2006 (CDT)

 View with fixed-width fonts
 This has not yet been validated for proper operation, and may not have ever been implemented.
 Automatic [ Charge - PHEV Drive - Regen ] Mode Change, LV Layout
                 (-)12v Acc(+)
                  |         |
           |======#         |========|
           |  ____|____          ____|____
           |  !   #   !          !   #   !
 (-)12v    |  !   \   !          !   \   !      (+)12v
 When======#===#%,%\%#===|   |====#%,%\%#=======(Brown)
 AC Exists    !_#___#_!  |   |   !_#___#_!      Key On
                |   |    |   |     |   |
 MM-PFC=========|   #====|===|     |   |
LowCurrent          |    |         |   |
if 110vac           |    |=========|===|
                    |              |
 OEM (-) Contactor  |              |
 Leg (Black)========|              |   AC/Run Interlocks
...................................|.....................
                                  (+)
         |=========================|
         |
         |  SPDT
         #===NO==(Coil 01 & Coil 02), MM-PFC Vset Ni-Low=======(-(1) 12v)===#
         |       (Cap to Delay Opening and Closing)                         |
         |                                                                  |
         |  SPDT                                                            |
         #===NO==CAN-RL4, Coil 04 (Pb->MM-PFC, Power On)=======(-(1) 12v)===#
         |       (No Cap, Opens and Closes Instantly)                       |
         |                                                                  |
         |  SPDT                                                            |
         #===NO==CAN-RL2+3, (SOC Driver) MM-PFC Vset Ni-High===(-(1) 12v)===#
         |                                                                  |
         |                                                                  |
         |                                                                  |
         |  (-) 12v=!=NC======================!=============>==(-(1) 12v)=>=#
         |          !DPDT  CAN-RL5+6, (Regen) !
         #==========!=NO======================!=Coil 03===(-) 12v
                   (  Remove (-(1) 12v) Coil 04 Drops Immediately  )
                   (                    Coil 01&02 Delayed        )
                   (                    Coil 03 Delayed More      )
                   (  Adding (-(1) 12v) Coil 03 Drops Immediately  )
                   (                    Coil 01&02 Delayed        )
                   (                    Coil 04 Delayed More      )
 --Rjf 00:24, 22 June 2006 (CDT)

[edit] Enhanced Regen Ideas

Regen may need to transfer power through the OEM HAL sensor in order to:

  • Avoid Negative State Of Charge Drift which may not work like +Drift.
  • Allow current to be counted instantaneously and thus recover from or avoid CCL.
  • Allow for the use of the Prius as a DC Genset if PFC sources NiMH pack.

Potential Enhanced Regen methods

  • Use the PFC as is, switch Input/Output and change voltage setpoint.
    • Modify the PFC so it can move 2x amps in DC modes only.
    • Use a PFC power stage.. so we can stuff 150 amps in any direction.
  • Use a Honking Big diode and a properly sized PbA Pack.
  • Use a contactor and a diode and a properly sized PbA Pack.

[edit] Single Regulator Hack

At least one analog MK2 (modified for under voltage regulation), or a digital Mk 3 Reg is required to prevent the PFC charger from over-discharging the PHEV battery pack. Ideally a full set of regulators would be installed such that they would perform both over and under voltage protection as well as power regulations for every battery in the pack. If digital MK3 Regs are used they may also be able to report PHEV battery pack statuses back to the CAN-View interface or an external data logging device. If you only have one regulator then it should be installed on the weakest battery in your pack, and should only be connected to that battery during PHEV operation. Below is part of a wacky circuit to enable the easy switching of a single reg between multiple batteries within a pack.

 View with fixed-width fonts
 This has not yet been validated for proper operation, and may not have ever been implemented.
              |Batt|         .           |Batt|         .           |Batt|         .
+12-o----o    +1 HV-         . o----o    +2 HV-         . o----o    +3 HV-         .
    |    |    |    |   _=_   . |    |    |    |   _=_   . |    |    |    |   _=_   .
    o---~:~--~:~--~:~--o o--G. o---~:~--~:~--~:~--o o--G. o---~:~--~:~--~:~--o o--G.
         |    /    /         . |    |    /    /         . |    |    /    /         .
-12--G  n|c  n|o  n|o        . |   n|c  n|o  n|o        . |   n|c  n|o  n|o        .
         |    |    |         . |    |    |    |         . |    |    |    |         .
         o----|----|-----------o    o----|----|-----------o    o----|----|---------...(^n HV)
(n HV-)-------|----o---------------------|----o---------------------|----o---------...
(n HV+)-------o--------------------------o--------------------------o--------------...
                             .                          .                          .
       |         _=_      --~:~--     --~:~--   . Each set of 3 relays coils are in parallel  
     --o--     --o o--       |           /      . Any enabled set disables those downstream  
   Junction    Switch     nc relay    no relay  . Result: "n HV" should always be isolated    
--Rjf 20:34, 5 December 2008 (CST)

A battery from the pack is selected by grounding the desired "switch". This could be done with a rotary switch or perhaps some sort of more advanced digital timer or push to select circuit. It could even be done with individual toggle or dip switches as it should be safe to have multiple batteries selected as only the first enabled unit will be forwarded as it disables the remaining units. This may make it easier to scan the battery pack by hand to log voltages or find the weakest battery and then leave the circuit pointed to that one during operation. The regulators may draw substantial current from an over voltage battery while actively regulating, so be sure that the wire and relays are of a high enough gauge, or disable the regulation function.

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