General Disclaimer: (HV) (DC) injury or death hazard, use at your own risk, may void warranty. |
PriusPlus History-Schematics
This is where you will find schematics, PCB layout, and parts lists for the PriusPlus conversions. We hope to have up to date PCB and Parts Lists by early April.
PriusPlus Schematics
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- SOC & Control Schematic
- The control schematics contains various runlevel interlocks and manages the other parts of the conversion.
- Battery Tap Emulator Schematic
- The Battery Tap Emulator board also contains the State Of Charge Manipulation circuit and a set of relays which allows for the stock battery pack and it's native taps to be used if nessecary.
- High Power Schematic
- The High Voltage Schematic deals with all the high voltage connections, relays, fuses, and the battery pack itself.
Changes from V1 to V2
Version 2c schematics are now available, some of the changes since Version 1 are:
- Add the ability to switch back to the OEM battery pack at will (important for PbA battery packs, which are unreliable at low temperatures. Also handy during the testing process and perhaps to preseve a full charge for demonstration at a destination)
- Improve compatability with CAN-View, which will now be the first and recommended Prius PHEV User Interfaces or BMS spoofing and EV-mode automation system (Ron is actively working with Norm, CAN-View's creator, to ensure effective automation algorithms)
- Move all high voltage circuitry off the low power control board
As part of a Prius conversion to be done over the course of the Inaugural Maker Faire, April 22-23, we will be dramatically improving the documentation of the basic PbA PRIUS+ conversion process. We will also be publishing complete parts and supplier lists (Which are currently out of date at Version 1) and designing prited circuit boards for the electronics, which we will find some way to get produced for sale afterwards. If you live close enough to get there, please join us to observe a real conversion in process.
Control Schematic
The control schematics contains various runlevel interlocks and manages the other parts of the conversion.
Prius PHEV Schematics Control Board Parts List | ||||||||
Reference | QTY | Description | Vendor | Vendor # | DigiKey # | Cost | Price | Comments |
R1 - R8 | 8 | 1.2K Ohm 0.25W 5% Carbon Film Resistor | Panasonic | ERD-S2TJ122V | DigiKey:P1.2KBACT-ND | $0.54 | $0.07 | |
R9, R23 | 2 | 6.2K Ohm 0.25W 5% Carbon Film Resistor | Panasonic | ERD-S2TJ622V | DigiKey:P6.2KBACT-ND | $0.14 | $0.07 | |
R11, R18 | 2 | 5.1K Ohm 0.25W 5% Carbon Film Resistor | Panasonic | ERD-S2TJ512V | DigiKey:P5.1KBACT-ND | $0.14 | $0.07 | |
R12,13,16, 17, 22 | 5 | 100K Ohm 0.25W 5% Carbon Film Resistor | Panasonic | ERD-S2TJ104V | DigiKey:P100KBACT-ND | $0.34 | $0.07 | |
R14,15,28 | 3 | 1.0 Meg Ohm 0.25W 5% Carbon Film Resistor | Panasonic | ERD-S2TJ105V | DigiKey:P1.0MBACT-ND | $0.20 | $0.07 | |
R21,24,26 | 3 | 15K Ohm 0.25W 5% Carbon Film Resistor | Panasonic | ERD-S2TJ153V | DigiKey:P15KBACT-ND | $0.20 | $0.07 | |
R25 | 1 | 47K Ohm 0.25W 5% Carbon Film Resistor | Panasonic | ERD-S2TJ473V | DigiKey:P47KBACT-ND | $0.07 | $0.07 | |
R27 | 1 | 2K Ohm 0.25W 5% Carbon Film Resistor | Panasonic | ERD-S2TJ202V | DigiKey:P2.0KBACT-ND | $0.07 | $0.07 | |
R10 | 1 | 2K Ohm 1 turn trimpot - top adjust | MuRata | PVC6M202C01B00 | DigiKey:490-2815-ND | $1.05 | $1.05 | |
R20 | 1 | 5K Ohm 1 turn trimpot - top adjust | MuRata | PVC6M502C01B00 | DigiKey:490-2826-ND | $1.05 | $1.05 | |
C1 | 1 | 0.1 uF Metallized Polypropylene Film Cap | Epcos | B32621A5104J | DigiKey:495-1375-ND | $0.54 | $0.54 | radial leads, 10 mm spacing, Very Good self healing properties |
RL1, 3, 4 | 3 | SPDT Relay, 10-15V coil, 10 A, 15 V contact | Omron | LY1-DC12 | DigiKey:Z785-ND | $19.35 | $6.45 | |
RL2 | 1 | DPDT Relay, 10-15V coil, 10 A, 15 V contact | Omron | LY2-DC12 | DigiKey:Z790-ND | $7.58 | $7.58 | |
RL5 | 1 | 4PDT Relay, 10-15V coil, 1 A, 15 V contact | Omron | MY4-DC12(S) | DigiKey:Z186-ND | $6.48 | $6.48 | |
RS1, 2, 3, 4 | 4 | Relay Socket for RL1, 2, 3, 4 | Omron | PT08-0 | DigiKey:Z792-ND | $27.00 | $6.75 | |
RS5 | 1 | Relay Socket for RL5 | Omron | PY14-02 | DigiKey:Z813-ND | $1.80 | $1.80 | |
D6, D9 | 2 | Silicon Rectifier - 100V, 1 A | Diodes, Inc. | 1N4002-T | DigiKey:1N4002DICT-ND | $0.52 | $0.26 | DO-41 Package |
D1-D5, 7, 8 | 7 | High Speed Diode - 1N4148 | Philips | 1N4148 T/R | DigiKey:568-1360-1-ND | $0.35 | $0.05 | DO-35 Package |
U1A,B,C | 1 | Quad Comparator IC 0-70Deg C 14-DIP | Fairchild | LM339AN | DigiKey:LM339ANFS-ND | $0.55 | $0.55 | 14 pin DIP package |
Q1 - Q4 | 4 | NPN Transistor, 10 A, 60 V | ST Microelectronics | MJE3055T | DigiKey:497-2573-5-ND | $3.36 | $0.84 | TO-220 Package |
Q5 | 1 | PNP Darling Transistor, 5 A, 100 V | Fairchild | TIP127 | DigiKey:TIP127FS-ND | $0.63 | $0.63 | TO-220 Package |
Q6, Q7 | 2 | PNP Transistor, 200 mA, 40 V | Fairchild | 2N3906BU | DigiKey:2N3906FS-ND | $0.36 | $0.18 | TO-92 package |
J1M | 1 | 8 Pin PC Board connector - control board power | Molex | 26-60-5080 | DigiKey:WM4646-ND | $0.96 | $0.96 | 0.156 inch spacing |
J2F | 1 | 6 Pin PC Board connector to HV Board | Molex | 22-15-2066 | DigiKey:WM3004-ND | $0.86 | $0.86 | 0.1 inch spacing |
J3M | 1 | 8 pin Connector to CAN View | Molex | 22-05-3081 | DigiKey:WM4306-ND | $1.26 | $1.26 | 0.1 inch spacing |
J4M | 1 | 6 Pin PC Board connector (Interlock) | Molex | 26-60-5060 | DigiKey:WM4644-ND | $0.83 | $0.83 | 0.156 inch spacing |
J5M | 1 | 10 pin right angle ribbon cable header with latches, (to battery ECU) | Amp | 499913-1 | DigiKey:AHB10G-ND | $1.99 | $1.99 | |
J6M | 1 | 16 pin right angle ribbon cable header with latches, (LED Debug Cable) | Amp | 499913-3 | DigiKey:AHB16G-ND | $2.20 | $2.20 | |
BBXJ3M,J13M, J14M | 5 | 2 pin Connector to Control Board | Molex | 22-05-3021 | DigiKey:WM4300-ND | $2.75 | $0.55 | 0.1 inch spacing |
U1S, S1S | 2 | 8 pin DIP IC socket | Amp | 2-640463-2 | DigiKey:A24794-ND | $0.84 | $0.42 | Use with S1 and U1 |
S1 | 1 | SPST Dip Switch | CTS | 206-4 | DigiKey:CT2064-ND | $0.59 | $0.59 | 4 position switch - just use 1 position |
Total cost | $84.60 |
Battery Tap Emulator Schematic
The Battery Tap Emulator board also contains the State Of Charge Manipulation circuit and a set of relays which allows for the stock battery pack and it's native taps to be used if nessecary.
Prius PHEV Schematics High Voltage Board, (Tap Emulator) Parts List | ||||||||
Reference | QTY | Description | Vendor | Vendor # | DigiKey # | Cost | Price | Comments |
R1 - R14 | 14 | 1K Ohm 0.5W 1% Metal Film Resistor | Phoenix Passive Components | 5033ED1K000F12AF5 | DigiKey:PPC1.00KXCT-ND | $2.72 | $0.19 | |
R16, R24-27 | 5 | 100K Ohm 0.25W 5% Carbon Film Resistor | Panasonic | ERD-S2TJ104V | DigiKey:P100KBACT-ND | $0.34 | $0.07 | |
R17 | 1 | 10K Ohm 0.25W 5% Carbon Film Resistor | Panasonic | ERD-S2TJ103V | DigiKey:P10KBACT-ND | $0.07 | $0.07 | |
R18 | 1 | 49.9K Ohm 0.5W 1% Metal Film Resistor | Phoenix Passive Components | 5033ED49K90F12AF5 | DigiKey:PPC49.9KXCT-ND | $0.19 | $0.19 | |
R19, R30 | 2 | 200K Ohm 0.25W 5% Carbon Film Resistor | Panasonic | ERD-S2TJ204V | DigiKey:P200KBACT-ND | $0.13 | $0.07 | |
R20 | 1 | 160K Ohm 0.25W 5% Carbon Film Resistor | Panasonic | ERD-S2TJ164V | DigiKey:P160KBACT-ND | $0.07 | $0.07 | |
R21, R23 | 2 | 47K Ohm 0.25W 5% Carbon Film Resistor | Panasonic | ERD-S2TJ473V | DigiKey:P47KBACT-ND | $0.13 | $0.07 | |
R29 | 1 | 56K Ohm 0.25W 5% Carbon Film Resistor | Panasonic | ERD-S2TJ563V | DigiKey:P56KBACT-ND | $0.07 | $0.07 | |
R33 | 1 | 470 Ohm 0.25W 5% Carbon Film Resistor | Panasonic | ERD-S2TJ471V | DigiKey:P470BACT-ND | $0.07 | $0.07 | |
R35 | 1 | 470K Ohm 0.25W 5% Carbon Film Resistor | Panasonic | ERD-S2TJ474V | DigiKey:ERD-S2TJ474V | $0.07 | $0.07 | |
R31 | 1 | 200K Ohm 0.5W 1% Metal Film Resistor | Phoenix Passive Components | 5033ED200K0F12AF5 | DigiKey:PPC200KXCT-ND | $0.19 | $0.19 | |
R36 | 1 | 1.0 Meg Ohm 0.5W 1% Metal Film Resistor | Phoenix Passive Components | 5033ED1M000F12AF5 | DigiKey:PPC1.00MXCT-ND | $0.19 | $0.19 | |
C1 - C15 | 15 | 0.1 uF Metallized Polypropylene Film Cap | Epcos | B32621A5104J | DigiKey:495-1375-ND | $8.10 | $0.54 | radial leads, 10 mm spacing, Very Good self healing properties |
C16 | 1 | 0.01 uF Metallized Polypropylene Film Cap | Epcos | B32621A3103J | DigiKey:495-1283-ND | $0.37 | $0.37 | radial leads, 10 mm spacing |
R15, R28 | 2 | 25K Ohm 1 turn trimpot - top adjust | MuRata | PVC6M253C01B00 | DigiKey:490-2822-ND | $2.10 | $1.05 | |
R22, R34 | 2 | 50K Ohm 1 turn trimpot - top adjust | MuRata | PVC6M503C01B00 | DigiKey:490-2827-ND | $2.10 | $1.05 | |
RL1 | 1 | SPST-NO DIP Reed Relay - 12V with diode | Hamlin | HE721A1210 | DigiKey:HE103-ND | $1.79 | $1.79 | |
RL2 - RL5 | 4 | 4PDT Power Relay 3A 12VDC | Omron | MY4-DC12(S) | DigiKey:Z186-ND | $25.92 | $6.48 | elliptical leads |
RS2 - RS5 | 4 | Relay Socket for RL2 - RL5 | Omron | PY14-02 | DigiKey:Z813-ND | $7.20 | $1.80 | PCB Mounting |
D2 | 1 | Silicon Rectifier - 100V, 1 A | Diodes, Inc. | 1N4002-T | DigiKey:1N4002DICT-ND | $0.26 | $0.26 | DO-41 Package |
D4 | 1 | Silicon Rectifier - 200V, 1 A | Diodes, Inc. | 1N4003-T | DigiKey:1N4003DICT-ND | $0.26 | $0.26 | DO-41 Package |
D1, D3, D5-D9 | 7 | High Speed Diode - 1N4148 | Philips | 1N4148 T/R | DigiKey:568-1360-1-ND | $0.35 | $0.05 | DO-35 Package |
D10 | 1 | 91 Volt Zener Diode - 2 W, 5% | MicroSemi | 2EZ91D5DO41 | DigiKey:2EZ91D5DO41MSCT-ND | $1.42 | $1.42 | DO-41 package |
D11 | 1 | 120 Volt Zener Diode - 2 W, 5% | MicroSemi | 2EZ120D5DO41 | DigiKey:2EZ120D5DO41MSCT-ND | $1.42 | $1.42 | DO-41 package |
Q1, Q4, Q5 | 3 | NPN Darlington Transistor, 5 A, 100 V | Fairchild | TIP122 | DigiKey:TIP122FS-ND | $1.80 | $0.60 | TO-220 Package |
Q2, Q6, Q7 | 3 | NPN Transistor, 500 mA, 300 V | Fairchild | MPSA42 | DigiKey:MPSA42FS-ND | $1.08 | $0.36 | TO-92 Package |
Q8 | 1 | PNP Transistor, 500 mA, 300 V | Fairchild | MPSA92 | DigiKey:MPSA92-ND | $0.36 | $0.36 | TO-92 Package |
J8M | 1 | 16 pin right angle ribbon cable header with latches | Amp | 499913-3 | DigiKey:AHB16G-ND | $2.20 | $2.20 | |
J7M | 1 | 20 pin right angle ribbon cable header with latches | Amp | 499913-4 | DigiKey:AHB20G-ND | $5.18 | $5.18 | |
J2M | 1 | 6 pin Connector to Control Board | Molex | 22-05-3061 | DigiKey:WM4804-ND | $1.23 | $1.23 | |
J13M | 1 | 5 Position Header Connector .156" right angle | Molex | 26-60-5050 | DigiKey:WM4643-ND | $0.64 | $0.64 | |
PS1 | 1 | Isolation Power Supply 12 VDC to +/- 15 VDC | V-Infinity | PTK10-Q24-D15 | DigiKey:102-1233-ND | $39.24 | $39.24 | 1 in. x 2 in. x 0.4 in. |
Total cost | $107.26 |
High Power Schematic
The High Voltage Schematic deals with all the high voltage connections, relays, fuses, and the battery pack. Prius PHEV Schematics High Voltage Parts List
Parts List Version 2c.:
- F1-4 : LPJ-60SP fuse in JT60060 finger-safe holder
- F3,4 : AGC 1/4A, 1250VAC fuse in HFA holder
- F5 : ATC-15 32V blade fuse in HHD in-line holder
- Thr1-4 : thermister, 10K @ 25 deg C, -4.40%/degC DigiKey:KC003T-ND or DigiKey:KC009G-ND
- more...
Parts List Version 1a.:
- F1 - 4 = Bussman LPJ-60P fues in Bussman JT60060 holder
- F6 - 7 = 0.5A 3AG inline fuse
- Thr1-4 = thermister, 10K @ 25 deg C
- Battery ECU plug replaced with Wire Frame, Toyota P/N 82165-47040 (part of battery tap)
- HVRL1 = Kilovac EV200
- Misc Anderson PP180 & PP15 connectors single pole multi pole
- The contactor, welding cable, economy welding cable crimper, lugs, fans, miscellaneous equipment and electronics supplies, including the isolated DC power supply, are available at http://www.kta-ev.com/catalog/index.html