Toyota Prius Gen 2 Inverter Controller

[MattsAwesomeStuff]

In the "Do-ocracy" sense, as in, those willing to do the work decide how it's done, I have nothing to interfere.

But, I presume anyone wanting to create a JLPCB version of the Gen2 inverter is not going to be using the Blue Pill anymore, and just using the STM32 right?

A possible challenge is that Damien had to reinterpret the circuit a bit (for the Gen3) to fit JLPCB's parts inventory, so, it's not quite as simple as just transcribing the schematic.

And... anyone going through the effort of doing that... should we make a feature list of things we'd like to see on the board? Duplicate the driver so it can do M1 and M2? Include charger support? DC support? Boost converter support? DC-DC 12v support?

My thinking is... I picked up an early version because I wanted to get rolling ASAP. With, somewhat being okay with buying a fancier version later. So for me, since I've already put ~$120 in parts into a test version, I would like to hang on (and support however I'm able) a complete board, not another in-between board.

But I will not be the one doing the work, so, just idle thoughts from me.

[kiwifiat]

I believe konstantin8818 would like to run a prius transaxle with his gen2 board. To do that he needs to condition the current sensor signals coming from the prius inverter so they can be read correctly by the STM32. As SciroccoEV has pointed out for a few $ in parts that can be done. In addition to run a PMSM with the Gen2 board a few more $ in parts and a bit of strip board the resolver interface can be constructed. That may not be a suitable solution for some but as Jack Bauer has observed it is not brain surgery.

Jack Bauer and yaroslav have both demonstrated that the bluepill can run an induction motor. johu fixed the issue with the pwm shutting down due to interference on the bk-in pin on the bluepill some time back. I personally plan using the bluepill on a Ford Escape hybrid transaxle not because it is the optimal solution but probably for the same reason Jack Bauer did the gen2 board in the first place, just for kicks and the fact that it is ridiculously cheap as was the transaxle @ $100CAD . It may not make a lot of sense but for me it is a fun exercise.

Anyone starting from scratch and lacking the required electronics skills has the option of the rev3 board as it has everything already onboard to run both induction and pmsm's.

[ZooKeeper]

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[RetroZero]

RetroZero is also planning on running the Gen 2 inverter and transaxle...Like Matt, I can only watch and learn, and at best be a crash test dummy. Willing to 'risk' ordering a Rev3 whilst the 'little worthwhile is easy part' continues. Planning to make up adapter between Mg1 & Mg2, but get her spinning first I say.

[konstantin8818]

I believe konstantin8818 would like to run a prius transaxle with his gen2 board.

Thank you for the update with capacitor.
For now I'm planning to test Damien's board with my ACIM motor which currently runs under curis 1236. I want to see what difference prius inverter can do. So all I need now is to wait untill my contactors arrive.
I've got no prius transaxle yet, but I've got Lexus MGR. I want to run it with Johu's board and for that I need that current sensor signal converter. As well as BUS voltage sensor signal devider.

[konstantin8818]

DC-DC 12v support?

Already works! Just need three wires, 12v x2 and 5v x1 (I just updated the Wiki )

I can't see any changes in wiki. Can you please show it here, wich wires goes where?

[mattndex@gmail.com]

Trying to upload a few pages of what I found. Is there a way we can share the Toyota manuals or it's illegal? For now just trying to upload screen shots of C5 connector signals.

[mattndex@gmail.com]

NODD and VLO are the ones giving me a headache at the moment because I don't have anywhere to test them.

[ZooKeeper]

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[johu]

Not sure if uploading the manuals is a good idea, better link to an existing source. Some excerpts should be fine though.
Is there any info on the part number of those control input connectors for the DC/DC converter (and aux inverter)?
Any info on the 2 pole connector for power, next to the 32-pin one?
Any info on the aux inverter in general?

[ZooKeeper]

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[ZooKeeper]

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[ZooKeeper]

Is there any info on the part number of those control input connectors for the DC/DC converter (and aux inverter)?

I attached a photo above with the pin map for the 12v DC-DC system, the p/n for the C5 connector shell is 90980-11034 and for the C6 90980-11963. Those are the only two external connections needed for the DC-DC to function. It is able to supply 100A of "12v" power, so should be fused accordingly.

Any info on the 2 pole connector for power, next to the 32-pin one?

That is THE 12v enable circuit for the internal inverter / converter systems, completely unrelated to the DC-DC converter functions, which is convenient. Connector p/n is 90980-11148, Red to "12v", black to Ground (vehicle common B-), draw is pretty low, will measure it and report when I get the damned blue-pill running.

Any info on the aux inverter in general?

Voltage output is between 13.2v & 15v nominal, depending on the voltage applied to the C5 #4 terminal. 5V results in 15.2 no-load volts, but I will be testing the loaded output in the next few days.

There is also a lid interlock connection, I plan on using that to complete the GROUND for the HV relay coils Lid off = no HV

[johu]

Awesome, thanks!

Any info on the aux inverter in general?

Voltage output is between 13.2v & 15v nominal, depending on the voltage applied to the C5 #4 terminal. 5V results in 15.2 no-load volts, but I will be testing the loaded output in the next few days.

Ah, by inverter I meant the small 3-phase inverter in the bottom, on the same PCB as the DC/DC converter

[ZooKeeper]

Awesome, thanks!

Ah, by inverter I meant the small 3-phase inverter in the bottom, on the same PCB as the DC/DC converter

Oh, yes. That is the inverter for the AC compressor, CAN controlled via the "BEAN" (????) network, I removed the wiring from mine as I consider it vestigial, but would be highly valuable to someone who needs Air Conditioning in their conversion!

[konstantin8818]

I could try to upload this picture to wiki.

If I understood correct, one 12V supply is monitoring one coming from battery and the other one is from ignition relay

[ZooKeeper]

I have both 12v wired to the "Ignition" circuit, there is no voltage monitoring on either wire from the documents I have. NODD (pin #4) and VLO (pin #5) are "responsible" for voltage conditioning, but VLO is not needed or even useful for our purposes.

Current draw is on my list to do , but 2A protection should be more than adequate.

[konstantin8818]

I have both 12v wired to the "Ignition" circuit, there is no voltage monitoring on either wire from the documents I have.

I believe there is a reason why one connector is hooked up straight to battery. Maybe converter itself monitoring voltage even when ignition is switched off.

[ZooKeeper]

Remember, this device works with engine OFF to supply 12v to vehicle loads in the factory configuration and it would be unwise to do so in an EV conversion. I suspect the B+ connection is related to that ability, but there is scant documentation in the book.

[konstantin8818]

Remember, this device works with engine OFF to supply 12v to vehicle loads in the factory configuration and it would be unwise to do so in an EV conversion. I suspect the B+ connection is related to that ability, but there is scant documentation in the book.

So you saying converter will drain 12v battery while being switched off?

[ZooKeeper]

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[konstantin8818]

Reading the book, there is no reason to connect any C5 terminal to B+ because the signals from other modules are not available. It should not hurt anything, but it is easier to connect one 12V Ign wire to two terminals, than to run two separate wires from 12V Ign and B+. In the end, it's a "serving suggestion", no harm either way from what I can tell.

Fair enough. I'll change picture on wiki right away.
EDIT: changed picture, also updated pictures of inverter's externals and internals

[ZooKeeper]

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[MattsAwesomeStuff]

I am able to get output from the DCDC with ONLY terminal #1 being tied to 12v as "ignition".

Heh, well, other than losing your mind, fewer wires is better for the rest of us :p

I've updated the wiki a bunch. I added notes about it having the AC compressor inverter (wasn't sure Gen2 had that). And I cleaned up and rewrote much of what you guys added. Please check it for stupidity, I only minimally understand the context.

Also, the image Konstantin uploaded is now obsolete (no pin 3 required), and also the writing on both of those images are almost impossible to see. I almost didn't notice the black writing. Larger and yellow if possible (just to be consistent with pin numberings above).

...

Random thought... what happens if your 12v battery is dead, and your HV battery is connected? You can't turn your DC-DC converter on, to have 12v, without having 12v, no?

...

Also, it's awesome how many people are working on and using the Gen2, and how many people are contributing to the wiki. Not that it's a competition, but, Gen2 prius people are the best, just sayin'.

[mattndex@gmail.com]

Pin #1 is labeled IGCT and is Ignition on according to this attachment.