Prius Gen2 adapter board development thread

[Jack Bauer]

Great work Johannes. Probably one of the most important developments on here.

[RetroZero]

Thanks Johannes and Damien! ORDERED!
Let the games begin

[Stephen Darbey]

Great stuff Johannes.
Serious news indeed. On my hit list within the next few weeks. I really hope this is the beginning of 'mass production of DIY conversions'

Regards
Stephen

[Bassmobile]

Stopping the torture: https://openinverter.org/shop/index.php ... duct_id=63

The kit includes all connectors (except the 2-pin gate drive power connector)

Where are the design files available for the adventurous and/or indigent?

[johu]

Where are the design files available for the adventurous and/or indigent?

Patreon
As suggested some new designs will be released for Patrons first and will appear on github with a few months delay.

[ZooKeeper]

Fantastic! A Car and control board in the same week, I wonder which will arrive first?

[Bassmobile]

Where are the design files available for the adventurous and/or indigent?

Patreon
As suggested some new designs will be released for Patrons first and will appear on github with a few months delay.

Thank-you for the reply.

Unfortunate though, as it appears the Patreon platform does not allow a Patron to support with cryptocurrency?!
For that matter, one can not buy products from the Openinverter webshop with crypto either.
ಠ_ಠ

EDIT: Cash.app supports Bitcoin! I was able to move funds from a ledger, into fiat and onto a virtual debit card to join in supporting. Thought others might find this info useful if they wish to support Openinverter with crypto.

[Kevin Sharpe]

Where are the design files available for the adventurous and/or indigent?

Patreon
As suggested some new designs will be released for Patrons first and will appear on github with a few months delay.

Thank-you for the reply.

Unfortunate though, as it appears the Patreon platform does not allow a Patron to support with cryptocurrency. For that matter, one can not buy products from your webshop with crypto either.
ಠ_ಠ

This is not difficult... if you want early access to the designs then support the developers on their chosen platforms

Now, bring this thread back on topic!

[RetroZero]

Hi theJohannes. The 2 pin power connector you are talking about is the "famous" additional 2 pin white 12V inverter power connector you were looking for?

[johu]

Hi theJohannes. The 2 pin power connector you are talking about is the "famous" additional 2 pin white 12V inverter power connector you were looking for?

Yes. I have now pulled the pins from it and put them into a screw terminal. The offers on the internet may or may not come with pins so I didn't bother.

Now, I fully wired up the inverter to the 12-pole connector with the following results

• Getting good linear DC voltage reading with udcofs=327 and udcgain=3.78
• The current sensors have different gain, the gain of MG2 current sensors is 3.18 and that of the MG1 sensors 6.37. Must somehow be solved in software. Until then the charge input current set point must be doubled.
• I seem to have a faulty buck/boost module. It sings really load when CSDN=12V and the CPWM signal never goes to 15V like the inverter PWM channels. Or am I missing something?

So I couldn't complete my mission to test the battery charging feature. Anyone have a left over buck/boost module (without inductor)? Yes I could just buy another inverter but my space is limited so I'd rather avoid it.

EDIT: whats the temperature curve for the heatsink sensor, anyone got that?

[Jack Bauer]

https://web.archive.org/web/20190222091 ... er-module/

[johu]

Ok, I gather from that

• as opposed to the MSDN signal which must be tied to 12V the CSDN signal must be tied to GND
• As opposed the the inverter PWM for the booster wants a push-pull signal. 0V turns lower switch on, 5V means all off, 10V turns upper switch on. And just PWMing between 0 and 10V will probably cycle between the two.

Will try that later.

[RetroZero]

Keep playing, you're sorting out the teething problems ...

[johu]

Alright, I tested and here is what I found:

• CSDN input can be left floating, not sure what it is supposed to do
• CPWM needs a push-pull signal of rather low impedance. I used a 500Ohm resistor to 12 (13.3V) and ended up with 9.8V on CPWM
• When CPWM=0V the top IGBT is on meaning the DC input is connected to the inverter DC bus
• When CPWM >= 5V the bottom IGBT is on meaning the DC input is shorted
• There is no input to CPWM that would turn both IGBTs off really?
• The higher the positive dutycycle, the lower the voltage bucked from DC bus to battery

So switching this via the ULN2003 inverts the duty cycle and we have "more duty cycle -> more output voltage" which is good. But when the ULN is off CPWM is high and thus shorts out the battery input. Bad!

So what could the charge procedure look like?

• Only pull up CPWM when we actually want to charge
• Precharge DC bus to rectified AC, so say 320V for single phase 230V AC
• Set duty cycle to match calculated output voltage to udcsw or udcnom (So say we see 400V and udcsw is 200 we set 50% duty cycle)
• Close AC and DC contactor (can be on same control signal)
• switch over to PI charge controller
• When AC is unplugged the inverter will power down and all contactors open. Same when BMS commands end of charge - which can also happen by setting chargecur to 0 via CAN

[MattsAwesomeStuff]

I actually understood most of that. Great to see progress made.

[arber333]

Well i am using Prius gen2 inductor in my EMW 3phase aircooled charger for long time now. I never figured how to use Prius buck/boost module so i just use Semicron 300A igbt with some big ass caps instead. Works up to 16kW from regular 22kW EVSE. Dont use CP signal yet though... That would be a goot thing to have with buck/boost charger.

[SciroccoEV]

CSDN input can be left floating, not sure what it is supposed to do

What happens if you pull it above 5.6v?

[kiwifiat]

Some useful info on the boost converter module here:

https://nicjam.es/projects/how-to-turn- ... er-module/

CSDN is boost converter shutdown.

[MattsAwesomeStuff]

Some useful info on the boost converter module here:
https://nicjam.es/projects/how-to-turn- ... er-module/
CSDN is boost converter shutdown.

That's the same link Damien just posted from Archive.org.

[kiwifiat]

Some useful info on the boost converter module here:
https://nicjam.es/projects/how-to-turn- ... er-module/
CSDN is boost converter shutdown.

That's the same link Damien just posted from Archive.org.

Sure, aside from the photos and schematics in my link that may or may not be of use to some people.

[johu]

What happens if you pull it above 5.6v?

I didn't try 5.6V but I pulled it to 12V which results in the module singing very loud.

[konstantin8818]

I'm really embarased to ask, but is there any chanse of less expensive kit to appear at the shop. Maybe, like, just the board itself?

[RetroZero]

Toys arrived this evening. Thanks Johu

[johu]

Toys arrived this evening. Thanks Johu

Cool, let us know how it goes

I'm really embarased to ask, but is there any chanse of less expensive kit to appear at the shop. Maybe, like, just the board itself?

I will consider it but probably not. I want to prepack as much as possible and every variation adds extra work.
You will find the design files on Patreon now and in a few weeks also on github. 5 boards from JLCPCB delivered are still cheaper than one complete kit. Just not pre-programmed and a lot messier to use.

[RetroZero]

Got some flashing lights tonight . However, I now need the password to connect to wifi please..(wasn't with the pinout notice.
Hope to start small and spin the AC compressor from 12V supply.