Custom built, large Ah HV Pack replacement

Discussion in 'Generation 1 Prius Discussion' started by TexomaEV, May 19, 2010.

  1. TexomaEV

    TexomaEV Member

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    SWEET - If you can dig up the schematic, it would be greatly appreciated. I built the one mentioned earlier, and it was working, up until I adjusted the LM317T pot to close to 0K, and blew it up. It was quite the ear ringing experience....... lol
     
  2. bwilson4web

    bwilson4web BMW i3 and Model 3

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    Pictures! Pictures!

    I was about to suggest a fuse but Murphy says a $.05 fuse will be protected by the $5 part!

    Bob Wilson
     
  3. TexomaEV

    TexomaEV Member

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    Should have used a fixed value resistor instead of the potentiometer, but had no clue what value to use. I know now, not to use a variable one..... lol

    It sounds like there's already a proven design out there, so I'm going to hold out for his schematic if possible, before resurrecting this one.
     
  4. bwilson4web

    bwilson4web BMW i3 and Model 3

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    Well anyone who hasn't 'let the smoke out', hasn't done anything.

    My foggy memory says the linear regulator likes a 1.2 V. dV to regulate. So for 100 ma., 1.2 / .1 ~= 12 ohm. Not a lot but it needs to be at least 1/4 watt resistor, 120 mW. For 500 ma, 1.2/.5 ~= 2.4 ohm, now you're looking at at more like a 1 W. resistor, 600 mW. Of course the regulator would be pretty toasty too so heat sink, lots of heat sink.

    Oh well, best wait for something a little less 'ad hoc.'

    Bob Wilson
     
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  5. TexomaEV

    TexomaEV Member

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    While, I'm waiting on the next chance to "Let the Smoke" out of something, does anyone have a schematic of the HV Battery pack for examination?

    Information I'd love to find:

    1. Module numbering - Which one is say for error code P3016
    2. Module sense wiring harness - Color coded schematic relative to the module pair it's connected to.
    3. Schematic of how/what the two HV halves are connected via contactor(s), fuse(s), etc.
    4. Anything related in detail to the HV battery itself.
     
  6. bwilson4web

    bwilson4web BMW i3 and Model 3

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    They are numbered 1-19 with P3011 (1), being adjacent to the control electronics.
    You'll need "Toytoa Prius Electrical Wiring Diagram," I have 2003 model, EWD493U. There isn't a lot of detail but the color code and signals are there.

    Bob Wilson
     
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  7. statultra

    statultra uber-Senior Member

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    Each module is 7.2 volts ( nominal ) and theres 38 modules. The battery is split in half with the service plug, 136-140 volts on each half

    These modules are organized in blocks, there are 19 blocks each with 15 volts roughly. These blocks have sensors that go to the battery ECU that measures each block voltage. The block is two modules hooked up in series.

    Not only toyota uses this design Honda also has blocks with 15 volts roughly

    im doing this all from my head so correct me if im wrong
     
  8. TexomaEV

    TexomaEV Member

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    Thanks -

    Reasoning for wanting detailed schematic, is to know exactly how everything is interconnected to each other, from the internal electronics, contactor, fuse, shunt, sense wiring, etc. Need the whole picture in front of me, when we disassemble the unit, and rebuild it using different battery chemistry/Ah, etc. Since it of course won't fit in the same housing, as the OEM, the new pack will be arranged differently. I just want to know for sure how all the electronic support items tie together, in order for the replacement battery to be as invisible to the rest of the car as possible. I ordered a CDROM manual, which stated it had schematics, we'll see.......
     
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