Prius Gen2 adapter board development thread

[NiHaoMike]

For the low current the precharge switch handles, it would be perfectly reasonable to use a MOSFET based SSR. Could even be DIYed using a MOSFET, isolation transformer, and 555 to supply the signal to the transformer.

[konstantin8818]

For the low current the precharge switch handles, it would be perfectly reasonable to use a MOSFET based SSR. Could even be DIYed using a MOSFET, isolation transformer, and 555 to supply the signal to the transformer.

For guys who good at electronics maybe it is, but for us simple gapers it is much easier to find salvaged junction box from Prius

[ZooKeeper]

At least in the US, SSRs are not a viable solution since most DC rated ones are priced in the $1.50 -$2/amp range.

[Bassmobile]

Open a new topic to discuss pre-charge circuit design.

[johu]

Erm guys can we take it back on topic, please

[johu]

Added Prius Gen2 parameters to the wiki: https://openinverter.org/wiki/Configura ... 2_Inverter
It is only inverter parameters. I will flash these on all boards from now on.

I will release the schematic and gerbers soon. For now I will not publish the eagle files because I don't want random people to delete the copyright info and sell the boards as their invention.

[RetroZero]

Nice one Johu. I'm hooking up pedal, temp sensors, simulating preharge and start at the moment. Saving values as I go along that hopefully can help.

[konstantin8818]

Added Prius Gen2 parameters to the wiki: https://openinverter.org/wiki/Configura ... 2_Inverter

May I ask why deadtime parameter is zero, isn't that a reason why Damien burnt capacitors in Gen 3 Inverter?

[jap]

May I ask why deadtime parameter is zero, isn't that a reason why Damien burnt capacitors in Gen 3 Inverter?
Screenshot_20200711-085421_Chrome.jpg

viewtopic.php?f=14&t=817&p=12662&hilit=deadtime#p12662

[SciroccoEV]

May I ask why deadtime parameter is zero, isn't that a reason why Damien burnt capacitors in Gen 3 Inverter?

That was my idea, go back to page 1 of this thread.

[konstantin8818]

That was my idea, go back to page 1 of this thread.

Got it, Damien's Gen 3 board controls high and low sides, so dead time must be set.

[LRBen]

Got the kit today!
It is all assembled now and I can connect via the Wifi. I'll play around with it some more this week and see if I can get some lights to flash on MG2 with 12v on the HV.

I think I am being stupid, but I can't find the wiki entry for this board? On the link I can find on the wiki it just talked about Damien's board.

[konstantin8818]

I think I am being stupid, but I can't find the wiki entry for this board? On the link I can find on the wiki it just talked about Damien's board.

I believe there is still no wiki page for this board, as not that many people who can fill up the article got that board on hands. Wiki here being filled by enthusiasts

[imwoody36]

Got the kit today!
It is all assembled now and I can connect via the Wifi. I'll play around with it some more this week and see if I can get some lights to flash on MG2 with 12v on the HV.

I think I am being stupid, but I can't find the wiki entry for this board? On the link I can find on the wiki it just talked about Damien's board.

me too, got the board. cant find the docs

[ZooKeeper]

No need for a Wiki IMO, the pinouts are on the sheet and the initial settings in this thread. So far, my board is soldered, wired and communicating, just need parameters and bus voltage! Should be very soon, hour or so, if not tens of minutes

[MattsAwesomeStuff]

We should probably create a page just for the inverter itself and the breakdown, and then from that link the two project pages that came out of it.

Even if it's not much more than a placeholder, it's going to mislead people if they can't find content about it.

[LRBen]

We should probably create a page just for the inverter itself and the breakdown, and then from that link the two project pages that came out of it.

Even if it's not much more than a placeholder, it's going to mislead people if they can't find content about it.

I think that would be a good idea. Even just the basic information from this thread would be fine with a very basic overview of putting it all together. If there was a page created for this project I would be happy to populate it with what I learn as I go.


I do have a question about the initial setup. On the info sheet it says to connect the 2 pole power connector to 12v and GND. Does that mean the 2 pole power connector to the 12v and GND on the control board pins or a 12v supply and GND?

I am assuming it means a 12v supply and GND as when I set it up like the attached photo I get nothing.

So just to clarify. I need a 12v supply and GND to the inverter board, and 12v supply and GND to the 2 pole power connector on the inverter itself?
Just want to make sure before I pop something.

[ZooKeeper]

Apparently I am too stupid to even run a pre-built and tested board.

I have signals and il1 & il2 changing but no lighbulbs and no motor spin. Gone thru the parameters I can find, added fslippnt and ampnom up and down with no effect at 12V (lightbulbs) and 165V (to MGR) and have no more than 0.1vac on the 3ph bus.

Most depressing this is. I will try and connect to the VCU with this computer and get the file downloaded, in hopes someone will notice some obvious error.

[LRBen]

I do have a question about the initial setup. On the info sheet it says to connect the 2 pole power connector to 12v and GND. Does that mean the 2 pole power connector to the 12v and GND on the control board pins or a 12v supply and GND?

I am assuming it means a 12v supply and GND as when I set it up like the attached photo I get nothing.

So just to clarify. I need a 12v supply and GND to the inverter board, and 12v supply and GND to the 2 pole power connector on the inverter itself?
Just want to make sure before I pop something.

Figured it out. Inverter needs 12v and ground, so does the control board. Got it running now and giving me a voltage reading on the HV DC line.
Next up for me is the delta light test.

[RetroZero]

Apparently I am too stupid to even run a pre-built and tested board.

I have signals and il1 & il2 changing but no lighbulbs and no motor spin. Gone thru the parameters I can find, added fslippnt and ampnom up and down with no effect at 12V (lightbulbs) and 165V (to MGR) and have no more than 0.1vac on the 3ph bus.

Most depressing this is. I will try and connect to the VCU with this computer and get the file downloaded, in hopes someone will notice some obvious error.

I had same problem....until I set the direction parameter to "permanently forward" - hope that helps

[MattsAwesomeStuff]

Apparently I am too stupid to even run a pre-built and tested board.

And if you are, so are the 1000 people who'll follow, so, keep at it and keep documenting.

The reason that not as many people have adopted this, is because even if 99% documented, if you have to learn 20% of what it takes to engineer the board to answer that last 1%, then it's too intimidating. We need lots of examples of lots of people making all the wrong presumptions about how things work, so we can hammer out good procedures.

[ZooKeeper]

I had same problem....until I set the direction parameter to "permanently forward" - hope that helps

Unfortunately, that is not my case, as I found that advice before I even powered up the inverter. What really gets me is the IL1 & IL2 are swinging +/-1A with my delta bulbs, but no volts or lighting.

[johu]

+/-1A is pretty much noise. Is the MG2 power stage enabled via MSDN pin (#25)?

[ZooKeeper]

Thanks Johu, that helps, but I have now really screwed myself. I wrote down a new, yet completely obvious Wifi PW and apparently had a fat-finger event while entering it.

[MattsAwesomeStuff]

I wrote down a new, yet completely obvious Wifi PW and apparently had a fat-finger event while entering it.

Yet another critical bug from Johannes, who can't even implement the most basic of features...