Prius PHEV Schematics

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

Original CalCars Method

Further development of the PriusPlus 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

Hybrid-Pack Method

There is no longer a need for the Battery Tap Emulator.

The HV interface with the original battery is made after the HAL sensor.

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

Contactor Based

No new Schematics for these methods yet...

PFC Based

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

Manual Anderson Quick Mode Change.

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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

Automatic Charge - PHEV Drive Mode Change

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Automatic Charge - PHEV Drive Mode Change
Pair of DPDT or 4PDT, and SPST (40+ Amps, 12v coils)

   [ DaGrid ]       coil 03 DPDT only available while RL4
   |        |       NC = Grid
Grid Lockout (NC)   NO = Regen
   |        |
   |--------|--(dc immune, ac interlock)
   |        |
   #========|============== coil 03 =============|
   |        |               (NO)                 |
   |        #============== coil 03 =============|========|
   |        |                                    |        |
  (+)[Grid](-)      (+)[PbA](-)        (-)[NiMH](+)[NiMH](-)Regen Mode?
   |        |        |       |          |        |  Inverter side of OEM contactor
   |        |        |       |          |        |
   |   |====|========#=======|==========|====|   |
   |   |    |                |          |    |   |
   |   |    |   |=======|    #======|   |    |   |
   |   |    |   |     __|____|__    |   |    |   |
   |   |    |   |     | # ,, # !    |   |    |   |
 __|___|____|___|__   !  ----  !  __|___|____|___|__
 ! #   #    #   # !   !  %%%%  !  ! #   #    #   # !
 !  \ , %%%% \ ,  !   !  coil  !  !  \ , %%%% \ ,  !
 !   \  coil  \   !   !___02___!  !   \  coil  \   !
 !___#___01___#___!               !___#___01___#___!
     |        |                       |        |
     |(+)  (-)|                       |(-)  (+)|
12  [PFC Input]                      [PFC Output]
Can we get a four poll tripple throw 40A, 60A, or 120A Contactor or Drum Switch?

     Charge Mode
00 - coil 01 open   = Grid -> PbA, Charge if AC is present.
00 - AC driven (Drive/coil 01/coil 03/RLx) interlocks.
01 - nothing changes, can't enguage RL4 without Key On.

     Power up sequence
10 - coil 01 closed = PbA -> NiMH, (PFC V set NiMH) Key On
11 - coil 02 closed = PbA (-)neg input, (PFC powers on) CAN-View Relay RL4 (Stock/PHEV Mode)
11 - CAN-View RL2 drives dither (PFC V set NiMH high).
11 - RL4 locks out AC input so plugging in while on won't change anything.

     Power down sequence
10 - 1. Drop coil 2, wait (PFC powers off)
00 - 2. Drop coil 1, wait (Grid -> PbA, PFC V set PbA)

     Regen Mode / Charge PbA Mode / ?Charge external mode?
110- While running regen mode, triggered by CAN-View RL3
   Execute power down sequence
100- 1. Drop coil 2, wait (PFC powers off)
000- 2. Drop coil 1, wait (Grid -> PbA, PFC V set PbA)
   Connect NiMH (via regen points) to Grid input, inside grid lockout contactor.
001- 3. coil 03 closed = NiMH(Regen) -> Grid Regenning
   When CAN-View RL3 goes from closed to open
000- 1. coil 03 open, wait (PFC powers off)
100- 2. coil 01 closed = PbA -> NiMH, (PFC V set NiMH)
110- 3. coil 02 closed = PbA (-)neg input, (PFC powers on)
   ? Charge external mode ?
--Rjf 03:53, 9 June 2006 (CDT)

Enhanced Regen

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.