HV Battery Assembly

HV Battery Assembly Power Supply The HV battery supplies power to MG1 / MG2 The auxiliary battery supplies power to HV ECU and Engine ECU (all ECU) When both are functioning properly, the vehicle will start 2 types of battery. - HV battery (DC201.6V) - Auxiliary battery (DC12V) HV Battery (DC 201.6V) Auxiliary Battery (DC 12V)

Service Plug Connector HV Battery Assembly Components Module Current Sensor Battery ECU SMR3 SMR2 SMR1 Service Plug Connector Resister

HV Battery Assembly Battery Module Nickel metal hydride (Ni-MH) battery (1.2V x 6 cells) x 28 modules = 168 cells = DC 201.6 V 28 Module (1.2V x 6 cells) x 28 modules = 168 cells x 1.2V = DC 201.6 V Module (1.2V x 6 cells)

HV Battery Assembly Battery ECU Maintains control of HV battery SOC (State of charge) Ensures battery capability Battery ECU CAN SOC Control Cooling Fan Control Electrical Leakage Detection for High-voltage System Diagnosis Function for HV Battery HV Battery Condition Detection Battery Cooling Fan Relay HV ECU Engine ECU A/C ECU Battery Cooling Fan Controller Voltage x 14 Temp. x 4 + Temp. Sensors (Thermistor) Service Plug Battery Cooling Fan Motor - Current Sensor HV Battery

HV Battery Assembly Battery ECU Controls SOC to match THS characteristics The SOC is maintained at approx, 60%. A margin is given for further recharging via regenerative braking Sends requests to HV ECU to obtain desired SOC SOC (State Of Charge)

HV Battery Assembly SOC Control When the SOC is dropped, battery ECU sends the “Charge Request” signal to HV ECU Battery ECU Charge Request Power Request HV ECU Engine ECU SOC Control Voltage (SOC) Charging Charge MG1 Drive HV Battery Engine

HV Battery Assembly SMR (System Main Relay) Turns ON / OFF the high-voltage circuit SMR3 SMR1 SMR turns ON / OFF the high-voltage circuit. SMR2

HV Battery Assembly STEP 1: SMR 1 / SMR 3  ON STEP 2: SMR 2  ON When the power is ON (READY ON) STEP 1: SMR 1 / SMR 3  ON STEP 2: SMR 2  ON STEP 3: SMR 1  OFF

HV Battery Assembly STEP 1: SMR 1 / SMR 3  ON STEP 2: SMR 2  ON When the power is ON (READY ON) STEP 1: SMR 1 / SMR 3  ON STEP 2: SMR 2  ON STEP 3: SMR 1  OFF

HV Battery Assembly STEP 1: SMR 1 / SMR 3  ON STEP 2: SMR 2  ON When the power is ON (READY ON) STEP 1: SMR 1 / SMR 3  ON STEP 2: SMR 2  ON STEP 3: SMR 1  OFF

HV Battery Assembly STEP 1: SMR 1 / SMR 3  ON STEP 2: SMR 2  ON When the power is ON (READY ON) STEP 1: SMR 1 / SMR 3  ON STEP 2: SMR 2  ON STEP 3: SMR 1  OFF

HV Battery Assembly STEP 1: SMR 2  OFF STEP 2: SMR 3  OFF SMR When the power is OFF STEP 1: SMR 2  OFF STEP 2: SMR 3  OFF

HV Battery Assembly STEP 1: SMR 2  OFF STEP 2: SMR 3  OFF SMR When the power is OFF STEP 1: SMR 2  OFF STEP 2: SMR 3  OFF

HV Battery Assembly STEP 1: SMR 2  OFF STEP 2: SMR 3  OFF SMR When the power is OFF STEP 1: SMR 2  OFF STEP 2: SMR 3  OFF

HV Battery Assembly SMR System diagram Inverter SMR2 HV Battery SMR1 Service Plug Resister Voltage Sensor HV Battery Current Sensor SMR1 SMR3 Interlock Switch (Inverter Cover) Battery ECU HV ECU Interlock Switch (Service Plug) Power Switch Power Source Control ECU Airbag Sensor Assembly Circuit Breaker Sensor

(Service plug grip disconnection, Inverter cover open) HV Battery Assembly SMR Shutdown control READY OFF At Collision When one of the following conditions occurs, HV ECU shutdowns the SMR. - Ready OFF operation is done by the driver. - The vehicle collided. - Inter lock switch is OFF. (service plug grip disconnection, inverter cover open) Interlock Switch OFF (Service plug grip disconnection, Inverter cover open)

HV Battery Assembly Service Plug Shut off the high voltage circuit manually Service Plug Service plug shuts off the high voltage circuit manually.

HV Battery Assembly Service Plug Power is shut off at HV battery midpoint to avoid high voltage electricity flowing into the circuit

HV Battery Assembly Service Plug It contains a interlock switch and fuse Service Plug Service Plug Grip Fuse Interlock switch is used for the SMR shutdown control. Cover Interlock Switch

Caution: Wear insulated gloves HV Battery Assembly Service Plug Caution: Wear insulated gloves [Removal] [Installation] [Removal] 1. Lift-up the lever of service plug. 2. Turn the lever. 3. Disconnect the service plug. [Installation] 1. Connect the service plug 2. Turn the lever 3. Push the lever downward until the click is heard Caution: Wear insulated gloves when connecting / disconnecting the service plug to prevent against electrical shock.

HV Battery Assembly Cooling System Battery ECU executes a command to switch cooling fan ON when battery temp. rises Cooling Fan Air Inlet Cooling Fan Controller Battery Module : Temp. Sensor

Cooling Fan Controller HV Battery Assembly Cooling System Cooling fan motor is stepless controlled Cooling Fan Controller Temp. Sensors (HV Battery) (V) 13 Cooling Fan Motor Duty Signal Cooling Fan Controller Output Voltage Battery ECU M 4 30 95 (%) A/C ECU Input Duty Ratio (from Battery ECU)

HV Battery Assembly Auxiliary Battery Auxiliary battery supplies power to headlights, audio, and all ECUs Auxiliary Battery Auxiliary battery (12V) supplies power to headlights, audio, and all ECUs. It is located at the luggage compartment.

Never use an ordinary battery HV Battery Assembly Auxiliary Battery Sealed-type battery is used Notice: Refrain from quick charging Because the battery fluid cannot be replenished Never use an ordinary battery Sealed-type battery is used. Notice: Refrain from quick charging. Because the battery fluid cannot be replenished. If the auxiliary battery needs to be replaced, replace it only with a 12V battery specially designed for the use of the PRIUS.

HV Battery Assembly Auxiliary Battery Jump Start Terminal ”+” terminal of auxiliary battery for jump start is used Jump Start Terminal ”+” terminal of auxiliary battery for jump start is used at the relay block.