General Disclaimer:   (HV) (DC) injury or death hazard,   use at your own risk,   may void warranty.

Difference between revisions of "PriusPlus History-Schematics"

From My wiki
Jump to navigation Jump to search
(reformatting, updated for new V2 images.)
(maillist link)
Line 1: Line 1:
 
{{TOCright}}
 
{{TOCright}}
  
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.
+
This is where you will find schematics, PCB layout, and parts lists for the [[PriusPlus]] conversions.
 +
 
 +
Per [[EAA-PHEV_Maillist:2006./3./40]] we hope to have up to date PCB and Parts Lists by early April.
  
 
==PriusPlus Schematics==
 
==PriusPlus Schematics==

Revision as of 09:34, 23 March 2006

This is where you will find schematics, PCB layout, and parts lists for the PriusPlus conversions.

Per EAA-PHEV_Maillist:2006./3./40 we hope to have up to date PCB and Parts Lists by early April.

PriusPlus Schematics

EAA-PHEV-PRIUS-Combined.png

Navigation Image



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 We will also be publishing complete parts and supplier lists (Which are currently out of date at Version 1) and designing prited circuit boards for the electronics, which we will find some way to get produced for sale afterwards.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

Control Schematic 2f.

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

Battery Tap Emulator 2g.

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

High Power Schematic 2d.

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