General Disclaimer: (HV) (DC) injury or death hazard, use at your own risk, may void warranty. |
Difference between revisions of "Prius PHEV Schematics"
(→Automatic Charge - PHEV Drive Mode Change: 1 more space) |
(→Automatic Charge - PHEV Drive Mode Change: fixed AC Sense & AC coil, may combine 01+02 into single state) |
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'''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 | + | __|________|__ +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) | ||
+ | | | | ||
| |====|======================================| | | |====|======================================| | ||
| | | | | | | | | | ||
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__|___|____|___|__ | | | __|___|____|___|__ | | | ||
! # # # # ! | | | ! # # # # ! | | | ||
− | ! \ , %%%% \ , ! | + | ! \ , %%%% \ , ! | | |
− | ! \ coil \ ! | + | ! \ coil \ ! (+)[PbA](-) (-)[NiMH](+)[NiMH]''[[#Enhanced Regen|(-)Regen Mode?]] |
− | + | !___#___03___#___! | | | | ''Inverter side of OEM contactor'' | |
− | |||
− | |||
− | |||
− | |||
| | | | | | | | | | | | | | ||
| |====|========#=======|==========|====| | | | |====|========#=======|==========|====| | | ||
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'''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''' | |
00000 - Grid -> PbA, (PFC V set PbA ''default'') | 00000 - Grid -> PbA, (PFC V set PbA ''default'') | ||
− | ////0 - 110v AC Present (DC immune) coil 01 | + | ////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 | + | ////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 | + | - 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^'' | |
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)'' | |
11011 - PFC V set NiMH high | 11011 - PFC V set NiMH high | ||
− | + | ----- '''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) | ||
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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)''' | |
− | |||
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'' | |
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)''' | |
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) | ||
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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]] | + | --[[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.