Prius Gen 3 Inverter Logic Board Support Thread

[Bigpie]

I can't get any output, 12v in pin 1, gnd in 11, 12v in 3 for forward direction.

30v PSU attached like so.

Scope probe on one of the MG2 outputs, the negative on the DC bus negative.

In the web UI I've done

Code: Select all

start 2
set fslipspnt 1
set ampnom 1

Signal remains the same regardless of the run mode is manual or stop

I'll try probing the 50 way connector MG2 a/b/c hi/lo tomorrow. I'm I missing something to startup in manual mode?

[konstantin8818]

Damien if you haven't donated the smoked board already. I would love to have it for my gen 3 Prius inverter as it would help me get my project off the ground and in return i would gladly do a pateron donation and pay for shipping.

I'm fine with it, if Damien haven't sent board to me yet.

[invokeperformance]

Damien if you haven't donated the smoked board already. I would love to have it for my gen 3 Prius inverter as it would help me get my project off the ground and in return i would gladly do a pateron donation and pay for shipping.

I'm fine with it, if Damien haven't sent board to me yet.

ok thank you soooooo much this means a lot to me!!!!

[Dylan Witt]

okay i have an interesting question and situation, ive ordered the control board for the gen three prius inverter, i have a toyota avalon hybrid transmission in my electric rx8 build, i plan on using a Tesla refrigerant to water cooler, to keep the inverter cool and motor/generator cool, i have planned on using lithium batterys for my testing but at the moment ill have to settle for four prius nimh batterys, but my question is, because im running both mg1 and mg2 with the gen three inverter, how would i connect a charger to charge the batteries, other than removing the generator wiring and connecting mains power to the connections on the inverter, what all would i need to rewire or switch to enable mains power when i want to charge it? and once i get done testing i will be adding a second gen prius inverter just for charging of the new lithium 350 volt battery pack. but for testing i want to use the gen three as both dual drives and a mains power charger i know software is still developing, also is there anyone that can help me with running the toyota avalon hybrid ac compressor separate from the avalon. i guess i would need a control board to switch off the compressor or slow speed when pressure rises or falls, i work on refrigerant systems and know the risk of blow outs, so i need it to be safe but yet be able to cool the cabin plus the tesla water cooler for my inverter and motor/generator assembly

[Dylan Witt]

did anyone get a conformation email on shipping of the control board when it was shipped out?

[Jack Bauer]

https://tools.usps.com/go/TrackConfirmA ... 99075IE%2C

[Dylan Witt]

thank you sir

[Bigpie]

Is 5v off and -5v on for the IGBT drivers?

I've getting sold 5v on R64 - R69 as soon as the inverter is powered on. Hitting start in manual mode and setting fslipspnt and ampnom doesn't get me a PWM on the gate drivers.

Appreciate any pointers getting the thing generating output.

[bobby_come_lately]

May have narrowed down my udc problem with @Bigpie's help. DC_BUS_1 is completely stable but DC_BUS_2 is not. Is it possible capacitor C60 is bad/badly soldered? Looks fine under magnifier but thinking about getting it replaced to check.

Think it's a 1nF cap from the schematics. Assuming that's correct?

[Bigpie]

Cheers for the Skype call. Now getting pwm. I'd assumed man up run ignored feedback loop all together. Changed encoder type did it. I'll update the wiki so no one else gets stuck on it.

EDIT

I have almost achieved rotation, open loop
https://photos.google.com/share/AF1QipM ... JxajZmUGln

[konstantin8818]

EDIT
I have almost achieved rotation, open loop
https://photos.google.com/share/AF1QipM ... JxajZmUGln

It's like a song "One step forward, two steps back"...

[bobby_come_lately]

Cheers for the Skype call. Now getting pwm. I'd assumed man up run ignored feedback loop all together. Changed encoder type did it. I'll update the wiki so no one else gets stuck on it.

EDIT

I have almost achieved rotation, open loop
https://photos.google.com/share/AF1QipM ... JxajZmUGln

Amazing! Only a little bit jealous...

[Bigpie]

No idea why it's doing that, I'll have to do some reading and fiddling with the parameters.

You'll get there, let me know how you get on. I can help with (de)soldering if you want

[Dylan Witt]

Guys we might have a problem.... I was outside test driving my electric mazda rx8 with the Toyota Camry/Avalon hybrid transmission that’s installed in the rear of the car and directly connected to the wheels with modified axles, anyways I’m testing with a 72 volt 45amp Ebike controller, the max speed was 9mph or 14.4 kph and it accelerates to that speed in less than a second, but my problem is when you do the math at 350 volts that I’ll be running I’m only getting 44mph or 70kph, does this seem right? Or is the Prius inverter frequency capible of Driving the car faster?

[Isaac96]

The OpenInverter board is capable of using field weakening, which will allow higher speeds than dictated by the limits of the battery voltage. Note that at these higher speeds torque will be reduced.

Also I bet your ebike controller is not outputting a full 72 volts which also limits your speed.

Do you have any information on the Camry/Avalon transmission? It looks to me like it has two non-identical motor/generator units. Which are you turning? Is the input shaft locked?

-Isaac

[Dylan Witt]

Turning the drive motor, not generator, I haven’t locked anything yet, just because I’m wanting to make sure it will run correctly, I will be using both the motor and generator as a traction motor once I get the control board, but as long as I have good torque up to 40 mph then the field weakening might start to speed the car past 40mph I’ll be fine, I plan on just using the car as a show car for converting gas cars into electric cars and showing they can still be driven as if they were gas powered, which in my case I’ll still have more torque than the factory Stock 182hp rotary ever thought about

[Bigpie]

I'm not sure the 34 way connector included in the kit is the correct one for the socket, unless I'm doing it wrong which is more likely, it doesn't seem to want to 'mate'

The little tabs are fouling on the connector, anyone got this same issue?

[bobby_come_lately]

I'm not sure the 34 way connector included in the kit is the correct one for the socket, unless I'm doing it wrong which is more likely, it doesn't seem to want to 'mate'
20200705_183342.jpg
The little tabs are fouling on the connector, anyone got this same issue?

Which socket are you trying to plug it in to? That's the male socket AMPSEAL right? But it's not fitting into the female plug?

[Bigpie]

It's hard to get a photo that shows it but the grooves don't match the tabs.

is yours the same?

I've been filling more info on the wiki. Could you add details on your contactors and pre charge setup when you've time? I've not got that far

[Bigpie]

Problem solved. Not a massive issue, but I'll look in to part numbers and update/check BOM, I'm a bit obsessive when it comes to incorrect or out of date documentation.

[konstantin8818]

I've bought this TE connectivity 35-pin plug for Curtis five years ago and it's groove is differ from yours, and as I can see "notches" you made while trying to connect it, black connector is standart, but red one is different.

[Bigpie]

Yours looks like it might be the correct one. I think 776164-1 looks like the part you have, Konstantin, 776164-2 looks like what I have.

[Jack Bauer]

I don't supply plugs or sockets as part of the kit. That's up to the individual. In bigpie's case I had a few odd plugs so threw in one.

[Bigpie]

Gotcha, still would like to find part numbers for a matching pair for documentation purposes on the wiki.

[bobby_come_lately]

Gotcha, still would like to find part numbers for a matching pair for documentation purposes on the wiki.

Just been looking at the ones I've bought and they don't list the part numbers on the remaining documentation I have but it's definitely this one - 776164-1: https://uk.rs-online.com/web/p/automoti ... s/6809437/