Prius Gen 2 DCDC Converter

[johu]

The video is private

[tom3141]

- DC-DC provided stable output to over 360vdc applied at the HV Battery input

Are you saying here that it works with 360vdc applied?

I just re-ran the tests with new batteries in the meter and yes, the DC-DC was charging 14.1v @ 0.91A with 340vdc applied to the battery connections.

WOW!

<Edit: Video linked>

Well, that looks like very good news! I shall give it a try on mine to see if I get the same result.

[Ev8]

Strange how you can get 360v and I can’t get 288v to work perhaps something to do with me not going via the capacitor bank, or maybe to do with you slowly ramping voltage up to 360? Does it still work if you turn on with 360v applied?

[ZooKeeper]

The video is private

Fixed

[ZooKeeper]

Strange how you can get 360v and I can’t get 288v to work perhaps something to do with me not going via the capacitor bank, or maybe to do with you slowly ramping voltage up to 360? Does it still work if you turn on with 360v applied?

I tried to mimic the normal "start-up" process where the 12v circuits (Inverter, DCDC, VCU) are all on, then go thru the pre-charge routine.

Also, pins 1 & 3 are essentially supplied as if via "switched ignition" providing good voltage regulation @ 14.1v, when there is enough input power.

[Ev8]

Interesting I found that if I have the dc converter active whilst pre charging that pre charge never got over 120v because the converter goes active and starts taking all the current the pre charge resistor can pass so I had the converter behind another contactor in sync with the main contactor

[tom3141]

I’ve just done a quick test and was able to get an output from the DC-DC with a 320V+ battery pack. It was putting out 15.3v. This was with no load at all so guessing that might drop with a load. I did have pins 1 and 3 both connected.

[tom3141]

Does anyone have part numbers for the ‘C5’ connector and 12v output connector?

[Ev8]

Ok so with some changes to my pre charge setup mine is now behaving like everyone else’s and working at 288v hopefully my posts will help someone out who wants to run as voltages over 340v

[ZooKeeper]

I’ve just done a quick test and was able to get an output from the DC-DC with a 320V+ battery pack. It was putting out 15.3v. This was with no load at all so guessing that might drop with a load. I did have pins 1 and 3 both connected.

Yes, the DC-DC is a little wild with no loads, I found that as well. The second a 12v battery was in the circuit, output was rock-solid at 14.1v.

Does anyone have part numbers for the ‘C5’ connector and 12v output connector?

Sure: C5 = 90980-10987(F) & 10988(M) and C6 = 90980-11963.

[tom3141]

A 9.5mm female spade connector also fits the 12V DC-DC output terminal.

[tom3141]

I’d been having issues with the DC-DC not working most of the time, it would occasionally output 14V but mostly it wouldn’t output anything. Disconnected pin 3 (voltage regulation?) today and it’s now working fine. It does output just over 14V now (14.15V) but I’m not having the issues I had previously. Not sure what this means but it may be worth disconnecting pin 3 if you’re having issues.