Toyota MGR Rear Traction Transaxle

[tom3141]

Is there anyone who could confirm the resolver pinout on this?

I have Johannes Gen2 Inverter board connecting to an MGR. Zookeeper, as you have the same setup, could you confirm which pin on the 6 pin resolver connector connects to which pin on the 20 pin inverter connector?

[ZooKeeper]

Is there anyone who could confirm the resolver pinout on this?

I have Johannes Gen2 Inverter board connecting to an MGR. Zookeeper, as you have the same setup, could you confirm which pin on the 6 pin resolver connector connects to which pin on the 20 pin inverter connector?

The ONLY change from the diagram is JP2-23 is pin 5 "R2" on the VCU.

[tom3141]

Brilliant. Thank you!

[Jack Bauer]

Does anyone have the Toyota part number or numbers for the hv connector?

[tom3141]

I only have the extension piece, not the connector itself. If it’s any use the extension part number is 82090-48010, photo below

[ZooKeeper]

When I looked, the 3ph connection (wiring) was only available as part of some "engine harness" and really costly. I was lucky to get blunt-cut wires on mine

[tom3141]

I was thinking that I might cut away some of the aluminium on the extension piece so that I can drill a hole in the contact blades and connect that way.

[ZooKeeper]

I was thinking that I might cut away some of the aluminium on the extension piece so that I can drill a hole in the contact blades and connect that way.

I seem to remember seeing some TE female terminal in about their size, combined with insulation and a method to hold them all in place, might be an option worth looking into.

[bexander]

I also think you need to buy the hole harness, Toyota 821H1-48010. Also includes the connectors for the resolver and temp sensor.
I bought my harness used.

[ZooKeeper]

I confirmed the Resolver is 4 pole pairs and 2 resolver pairs. Setting to 2/1 produces irrational motor rpm.

< EDIT: Should read - "Resolver setting is 4 pole/2 resolver pairs".>

[Jack Bauer]

You mean the motor is 4 pole pairs and resolver 2? Thanks for the harness part number:)

[ZooKeeper]

Yes, 2 resolver, 4 pole. I tried 1r/2p and the rpm was just double, no obvious change to function.

[bexander]

Here is how I measured and confirmed that the MGR has 4 motor polepairs and 2 resolver polepairs.
viewtopic.php?f=14&t=488&p=15497#p15497
viewtopic.php?f=14&t=488&p=15534#p15534

[tom3141]

I can confirm that this part is the correct one for the resolver connector if anyone needs to purchase one separately.

https://www.ebay.co.uk/itm/233163662210

[ZooKeeper]

Yup, 11034 is the one and that is a good price.

[tom3141]

Managed to get my MGR spinning nicely on 30V tonight

Thanks to everyone who has contributed to these discussions and the wiki. It’s meant that I can get up and running with it very quickly. I’m happy to start trying to put together a wiki on the MGR if people think that it would be worthwhile?

I’m using a Prius Gen2 inverter with Johannes smd PCB wired as per the wiki schematic. The resolver is connected as per Zookeepers post above and phases as per Zookeepers photo below:

I tried using the exact same parameters as Zookeeper but ended up having to change syncofs. With syncofs at 43500 it spun ok in both directions but would slow down and get jerky as I increased throttle input. It also span the opposite way to the way it should (forward when reverse selected and vice versa).

I then went through the wiki procedure for tuning syncofs and a setting in the region of 7000-9000 seems best. Interestingly about 32000 less than Zookeepers which would explain the direction reversal. It now spins the correct way and will spin up to around 1000rpm in both directions until I hit the current limit of my power supply.

The plan now is to get it into my car as soon as possible to try it a full voltage (300v) and see what it can do.

[ZooKeeper]

I have 10 double-sided notebook pages of different syncof settings! Not a single one have I found to "really work" well, a few seem like they might work, but beyond some low throttle %, all I get is a huge spike in amps and trip out.

When I was testing at low voltage, it seemed like S.O. near 5k would work, then I upped to 48v and 9k-11k were in the spot, but if I got something wrong I initiated PLASMA from the protection devices Exciting, dangerous and educational.

I tried bigger S.O. leaps of around 5k and found 32768 would produce F=F and R=R about the time I realized w/o a step-by-step I was hopelessly lost.

Lastly I decided to go "off the reservation" and try to get some decent voltage (over 144 let's say ) and try to get SMOOTH spinning to see if the thing *could* turn fast enough w/o 650v certain people on the 'net claim is needed. Fortunately with my trusty Fluke, I have been able to carefully play at higher voltages and make small tweaks to syncof, MID, MIQ and get it spinning REALLY fast, at voltages that some said "will never work". LOL

It is nowhere near "right", but it is REALLY enjoyable to hear it happily spinning along for hours at a time at modest speed and <3A current while I ponder the next steps.

[tom3141]

Interesting. I don’t seem to have any issues with current spikes. Using the throttle I can spin smoothly in both directions up until I hit the 20A current limit on my PSU.

Has anyone figured out which pin is which on the 3 pin motor temp sensor connector?

[bexander]

On the motor temp sensor connector the pin1 and pin3 are used for the sensor. Pin2 is not used.
I don't know what type of sensor is used. It has a resistance of ~55kohms at ~20 degree C.

[ZooKeeper]

Interesting. I don’t seem to have any issues with current spikes. Using the throttle I can spin smoothly in both directions up until I hit the 20A current limit on my PSU.

@155v I can get nearly 7k RPM at 20A, but not with the throttle

I would *think* that using the "same" hardware, Prius G2, MGR + VCU should return similar, if not same syncof settings. If I recall Paul Holmes had one spinning quite nicely... Correction, yes he did

Has anyone figured out which pin is which on the 3 pin motor temp sensor connector?

I played around with the wiring and did not notice any data difference regardless of temp sensor "polarity" as it were.

[Jack Bauer]

Anyone know the thread on the oil drain and level check plugs?

[ZooKeeper]

16mm OD, very close to 1.5mm pitch, but I don't have a metric thread gauge to confirm.

[TheSilverBuick]

I think I have large enough metric thread gauges, I'll see if I can get a check on it in a couple hours.

[Jack Bauer]

Much appreciated.

[konstantin8818]

I would *think* that using the "same" hardware, Prius G2, MGR + VCU should return similar, if not same syncof settings. If I recall Paul Holmes had one spinning quite nicely... Correction, yes he did

I'm pretty shure that resolver calibration plug and three retaining bolts situated on the outside of the MGR is for good reason - to calibrate every single MGR on the production line. That means non of them have the same syncofs.