Section 3

High-Voltage Battery
Overview The sealed nickel−metal hydride (Ni−MH) battery technology developed
for the hybrid system provides both high power density and excellent
longevity. The hybrid system controls charge and discharge rates to
keep the HV battery at a constant State of Charge (SOC).

HV Battery Layout
The HV Battery, Battery ECU
and SMR (System Main Relay)
are enclosed in a single
case located in the luggage
compartment behind
the rear seat.

Figure 3.1 T071f301c

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Power Cable The power cable is a high−voltage, high−amperage cable that connects
the HV battery with the inverter and the inverter with MG1 and MG2.
In the ’04 & later Prius, the power cable also connects the inverter with
the A/C compressor.

The power cable is routed under the rear seat, through the floor panel,
along the under−the−floor reinforcement, and connects to the inverter in
the engine compartment. The 12V DC wiring harness follows a similar
route from the auxiliary battery to the front of the vehicle

The power cable is shielded to reduce electromagnetic interference.

For identification purposes, the high−voltage wiring harness and
connectors are color−coded orange to distinguish them from ordinary
low−voltage wiring.

Power Routing Cable

Figure 3.2 T071f302c

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HV - Nickel-Metal The HV battery pack contains six nickel−metal hydride 1.2V cells that
Hydride Battery are connected in series to form one module.

In the ’01−03 Prius, 38 modules are divided into two holders and
connected in series. Thus, the HV battery contains a total of 228 cells
and has a rated voltage of 273.6V.

In the ’04 and later Prius, 28 modules are connected for a rated voltage
of 201.6V. The cells are connected in two places to reduce the internal
resistance of the battery.

The electrode plates in the HV battery are made of porous nickel and
metal hydride alloy.

For battery recycling information, please refer to the Warranty Policy

NOTE
and Procedure manual.

HV Battery Pack
Information HV Battery Pack ’04 Prius and Later ’01-‘03 Prius

Battery pack voltage 201.6V 273.6V

Number of Ni-MH battery

28 38
modules in the pack

Number of cells 168 228

Ni-MH battery module ➝

7.2V
voltage

HV Battery
Main Components
(’04 & later Prius)

Figure 3.3 T071f303c

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Battery ECU The battery ECU provides the following functions:

• It estimates the charging/discharging amperage and outputs charge

and discharge requests to the HV ECU so that the SOC can be
constantly maintained at a center level.

• It estimates the amount of heat generated during charging and

discharging, and adjusts the cooling fan to maintain HV battery
temperature.

• It monitors the temperature and voltage of the battery and if a

malfunction is detected, can restrict or stop charging and
discharging to protect the HV battery.

Battery ECU
(’04 & later Prius)

Figure 3.4 T071f304p

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State Of Charge The battery ECU constantly monitors HV battery temperature, voltage
(SOC) and amperage. It also checks for leaks in the HV battery.

While the vehicle is in motion, the HV battery undergoes repetitive

charge/discharge cycles as it becomes discharged by MG2 during
acceleration, and charged by the regenerative brake during
deceleration. The Battery ECU estimates the charge/discharge
amperage and outputs charge/discharge requests to the HV ECU to
maintain the SOC at a median level.

The target SOC is 60%. When the SOC drops below the target range,
the battery ECU informs the HV ECU. The HV ECU then signals the
engine ECM to increase power to charge the HV battery. If the SOC is
below 20%, the engine is not producing power.

Delta SOC The normal, low to high SOC deviation is 20%. If the Delta SOC
exceeds 20%, this means that the HV battery ECU cannot correct or
maintain the SOC difference within the acceptable range.

SOC
The battery ECU outputs
requests to the HV ECU so
the SOC can be maintained
at a center level.

Figure 3.5 T071f305c

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System Main Relay The System Main Relay (SMR) connects and disconnects power to the
(SMR) high−voltage circuit based on commands from the HV ECU. A total of
three relays (one for the negative side and two for the positive side) are
provided to ensure proper operation.

When the circuit is energized, SMR1 and SMR3 are turned ON. The
resistor in line with SMR1 protects the circuit from excessive initial
current (called ‘inrush’ current). Next, SMR2 is turned ON and SMR1
is turned OFF, allowing current to flow freely in the circuit.

When de−energized, SMR2 and SMR3 are turned OFF in that order
and the HV ECU verifies that the respective relays have been properly
turned OFF.

System Main Relay

(SMR)
The SMR connects and
disconnects the power source
of the high-voltage circuit. A
total of three relays (one for
the negative side and two for
the positive side) are provided
to ensure proper operation.

Figure 3.6 T072f040c

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Service Plug When the service plug is removed the high−voltage circuit is shut OFF
at the intermediate position of the HV battery.

The service plug assembly contains a safety interlock reed switch.

Lifting the clip on the service plug opens the reed switch, shutting OFF
the SMR.

The main fuse for the high−voltage circuit is inside the service plug
assembly.

For safety reasons, you must always turn the vehicle OFF before
NOTE
removing the service plug.

HV Battery Cooling The battery ECU detects battery temperature via three temperature
System sensors in the HV battery and one intake air temperature sensor.
Based on those readings, the battery ECU adjusts the duty cycle of the
cooling fan to maintain the temperature of the HV battery within the
specified range.

The battery ECU keeps the fan OFF or running at LO if:

• The A/C is being used to cool the vehicle.

• Some margin is left in the temperature of the battery.

HV Battery Cooling
System
(’01-’03 Prius)

Figure 3.9 T071f309p

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HV Battery
Cooling System
(’04 & later Prius)

Figure 3.10 T071f310c

Auxiliary Battery The Prius uses an Absorbed Glass Mat (AGM) 12V maintenance free
auxiliary battery. This 12V battery powers the vehicle’s electrical
system similar to a conventional vehicle. The battery is grounded to
the metal chassis of the vehicle and vented to ambient (outside) air
with a tube.

This battery is very sensitive to high−voltage. When charging the

auxiliary battery you should use the Toyota approved charger, because
a standard battery charger does not have the proper voltage control
and may damage the battery. If the approved charger is not available
you may use a trickle charger if the amperage is kept below 3.5 A.

The battery should be removed from the vehicle during charging.

However, it is safe to jump−start the Prius from either the battery or
the jump−start terminal under the hood. This will allow the vehicle’s
charging system to restore the battery to normal SOC.

If the vehicle will not be used for more than two weeks, disconnect the
12V battery to prevent it from discharging. Always make sure that all
doors are properly closed and that the interior lights are OFF, especially
overnight. These situations will quickly deplete the 12V battery.

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Auxiliary Battery
In glass mat batteries, the
electrolyte is trapped in
separators to reduce the
amount of hydrogen gas
released when the battery
is charged.

Glass mat batteries are

sealed and the electrolyte
cannot be replaced.

Figure 3.11 T071f311c

Auxiliary Battery
Charging
(’04 & later Prius)

There is a remote access B +

terminal in the main junction
block under the hood, so it is
no longer necessary to
remove interior trim pieces to
gain access to the battery.

Figure 3.12 T071f312p

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WORKSHEET 3-1
Hybrid Diagnostic Trouble Codes

Vehicle Year/Prod. Date Engine Transmission

Worksheet Objectives
In this worksheet you will diagnose hybrid malfunctions by viewing DTCs, Information Codes, and the HV ECU
Data List.

Tools and Equipment

• Vehicle

• Diagnostic Tester

• Printer

• Repair Manual or TIS

Section 1: Hybrid Diagnosis

1. When starting the vehicle (READY light ON) do any warning lights illuminate? If so, which ones?

2. Connect the Diagnostic Tester to DLC3. Select Codes All to check all the ECUs.

3. How many systems are checked when using Codes All?

4. List the systems that show NG (No Good).

5. Now view the Information Codes by pressing enter on the systems that say NG, then press enter again.
Highlight the number next to INFORMATION and press enter.

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Section 3

6. Use the Repair Manual or TIS to look up the DTC and Information Code in order to find what part of the
system is affected. List this information below.

7. Is there any information in the HV ECU Data List that can help you diagnose the vehicle? If so, print and
highlight the information.

8. After diagnosing the vehicle, clear the codes and return to the classroom.

Hint: To clear DTCs, you must exit out of CODES ALL and enter each section individually.

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OYOTA HYBRID Battery
SYSTEM

SELF-ASSESSMENT 3-1
Hybrid Diagnostic Codes

Name: Date:

Self-assessment Objectives
Review this sheet as you are doing the Hybrid DTC Diagnosis worksheet. Check off either category after
completing the worksheet and instructor presentation. Ask the instructor if you have questions. The Comments
section is for you to write notes on where to find the information, questions, etc.

I have questions I know I can

Topic Comment
Locate vehicle warning lights.

View Codes All using the Diagnostic Tester.

View the Information Codes.

Use TIS & Repair Manual to research these

codes.
View the HV ECU Data List.

Clear Codes.

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