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

 View with fixed-width fonts This has not yet been validated for proper opperation
 Automatic [ Charge - PHEV Drive - Regen ] Mode Change
 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]
 coils     Can we get a four poll tripple 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 enguaging 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)

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.