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

Difference between revisions of "Prius PHEV Schematics"

From My wiki
Jump to navigation Jump to search
(→‎Automatic Charge - PHEV Drive Mode Change: fixed AC Sense & AC coil, may combine 01+02 into single state)
Line 58: Line 58:
 
   '''Automatic [ Charge - PHEV Drive - Regen ] Mode Change'''
 
   '''Automatic [ Charge - PHEV Drive - Regen ] Mode Change'''
 
   Pair of DPDT or 4PDT, DPDT, and SPST (40+ Amps, 12v coils)
 
   Pair of DPDT or 4PDT, DPDT, and SPST (40+ Amps, 12v coils)
     (+)[Grid](-)
+
     (+)[Grid](-)                Inputs --> State|Machine --> Outputs
       | coil 5 | (ac rated)
+
    __|________|__  +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)
 +
      |        |
 
       |  |====|======================================|
 
       |  |====|======================================|
 
       |  |    |                                      |
 
       |  |    |                                      |
Line 65: Line 71:
 
     __|___|____|___|__                                |        |
 
     __|___|____|___|__                                |        |
 
     ! #  #    #  # !                                |        |
 
     ! #  #    #  # !                                |        |
     !  \ , %%%% \ ,  ! coil 03 only while RL4=1      |        |
+
     !  \ , %%%% \ ,  !                               |        |
     !  \  coil  \  !                               |        |
+
     !  \  coil  \  !   (+)[PbA](-)        (-)[NiMH](+)[NiMH]''[[#Enhanced Regen|(-)Regen Mode?]]
    !___#___03___#___!                                |        |
+
    !___#___03___#___!    |      |          |        |  ''Inverter side of OEM contactor''
        |        |                                    |        |
 
      (+)      (-)      (+)[PbA](-)        (-)[NiMH](+)[NiMH]''[[#Enhanced Regen|(-)Regen Mode?]]
 
  (no dc|ac inter|lock)  |      |          |        |  ''Inverter side of OEM contactor''
 
        |        |        |      |          |        |
 
 
         |        |        |      |          |        |
 
         |        |        |      |          |        |
 
         |  |====|========#=======|==========|====|  |
 
         |  |====|========#=======|==========|====|  |
Line 88: Line 90:
 
   '''coils'''    '''''Can we get a four poll tripple throw 40A, 60A, or 120A Contactor or Drum Switch?'''''  
 
   '''coils'''    '''''Can we get a four poll tripple throw 40A, 60A, or 120A Contactor or Drum Switch?'''''  
 
   '''12345'''
 
   '''12345'''
        Charge Mode
+
  ----- '''Charge Mode'''
 
   00000 - Grid -> PbA, (PFC V set PbA ''default'')
 
   00000 - Grid -> PbA, (PFC V set PbA ''default'')
   ////0 - 110v AC Present (DC immune) coil 01&02&03&04&RLx interlock. (Set PFC Current < 15A)
+
   ////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&02&03&04&RLx interlock. (Leave PFC Current Full)
+
   ////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.
         Power up sequence '''Key On'''
+
        - 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
 
   00001 - open coil 05 (NC), ac interlock
 
   01001 - coil 02 Output -> NiMH, PFC V set NiMH low
 
   01001 - coil 02 Output -> NiMH, PFC V set NiMH low
 
   11001 - coil 01 Input -> PbA
 
   11001 - coil 01 Input -> PbA
        CAN-View "PHEV" Mode, Relay RL4^
+
          ''CAN-View "PHEV" Mode, Relay RL4^''
 
   11011 - Close coil 04 (NO), Connect PbA (-)neg leg (PFC On)
 
   11011 - Close coil 04 (NO), Connect PbA (-)neg leg (PFC On)
        CAN-View ?RL2^? (SOC/CCL Driven)
+
          ''CAN-View ?RL2^? (SOC/CCL Driven)''
 
   11011 - PFC V set NiMH high
 
   11011 - PFC V set NiMH high
        Power down sequence '''Key Off'''
+
  ----- '''Power down sequence Key Off'''
 
   11011 - Key On, and PHEV run state
 
   11011 - Key On, and PHEV run state
 
   11001 - Open coil 04 (NO), Disconnect PbA (-)neg leg (PFC Off)
 
   11001 - Open coil 04 (NO), Disconnect PbA (-)neg leg (PFC Off)
Line 107: Line 112:
 
   00001 - coil 02 Output -> PbA, PFC V Set PbA
 
   00001 - coil 02 Output -> PbA, PFC V Set PbA
 
   00000 - close coil 05 (NC), ac interlock
 
   00000 - close coil 05 (NC), ac interlock
    
+
   ----- '''CAN-View ?RL3^? (Enter Regen Mode)'''
      CAN-View ?RL3^? (Enter Regen Mode)
 
 
       1 - ''only while grid interlock is active''
 
       1 - ''only while grid interlock is active''
 
   11011 - Key On, and PHEV run state
 
   11011 - Key On, and PHEV run state
    Do Power down sequence '''Emulate Key Off''' less last state
+
          ''Do Power down sequence '''Emulate Key Off''' less last state''
 
   11001 - Open coil 04 (NO), Disconnect PbA (-)neg leg (PFC Off)
 
   11001 - Open coil 04 (NO), Disconnect PbA (-)neg leg (PFC Off)
 
   01001 - coil 01 Input -> Grid
 
   01001 - coil 01 Input -> Grid
 
   00001 - coil 02 Output -> PbA, PFC V Set PbA
 
   00001 - coil 02 Output -> PbA, PFC V Set PbA
 
   00101 - coil 03 NiMH(Regen) -> Grid Input (PFC On)
 
   00101 - coil 03 NiMH(Regen) -> Grid Input (PFC On)
      CAN-View ?RL3v? (Exit Regen Mode)
+
  ----- '''CAN-View ?RL3v? (Exit Regen Mode)'''
 
   00101 - Key On, and PHEV regen state
 
   00101 - Key On, and PHEV regen state
 
   00001 - coil 03 Grid -> Grid Input (PFC Off)
 
   00001 - coil 03 Grid -> Grid Input (PFC Off)
Line 122: Line 126:
 
   11001 - coil 01 Input -> PbA
 
   11001 - coil 01 Input -> PbA
 
   11011 - Close coil 04 (NO), Connect PbA (-)neg leg (PFC On)
 
   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''
 
   ''Forced PbA Charge Mode''
 
   ''(One could manually enter forced PbA charge mode by safely enguaging stationary regen '''?RL3^?)''
 
   ''(One could manually enter forced PbA charge mode by safely enguaging stationary regen '''?RL3^?)''
 
   ''Further, External Charging by:''
 
   ''Further, External Charging by:''
 
   ''(Shut off PFC, hyjack PFC output via Andersons, V tune (?independent?) and charge)''
 
   ''(Shut off PFC, hyjack PFC output via Andersons, V tune (?independent?) and charge)''
   --[[User:Rjf|Rjf]] 04:34, 14 June 2006 (CDT)
+
   --[[User:Rjf|Rjf]] 15:49, 14 June 2006 (CDT)
  
 
====Enhanced Regen====
 
====Enhanced Regen====

Revision as of 20:49, 14 June 2006

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.

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

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.