Prius Gen 3 Inverter Logic Board Support Thread

[bobby_come_lately]

Thoroughly enjoyed that. Interesting to see it topping out at around 50kw even in the acceleration burst on joining the motorway. Gives me faith my 60kw motor should be fine in a much smaller car.

[Dylan Witt]

Well here we go again, throttle, reads, started trying to tune the motor and once I started to turn the motor, wheels by hand the throttle pot jumped up and down, now I’ve double checked my wiring and I’m confused. I have no ideal what is going on.

[MattsAwesomeStuff]

Well here we go again, throttle, reads, started trying to tune the motor and once I started to turn the motor, wheels by hand the throttle pot jumped up and down, now I’ve double checked my wiring and I’m confused. I have no ideal what is going on.

Take a video. post it, link it. Can do an unlisted video if you don't want it to mess up your youtube channel.

If nothing else, the things you're not saying might be important or obvious.

And if not that, well, the rest of us can entertain ourselves by watching your failure. :p

[Dylan Witt]

So after getting some error I can’t explain and only setting Tmpm temp error, here is what I have.

[MattsAwesomeStuff]

Hmm...



So, your throttle pot seems to be behaving correctly, but your potnom is erratic and just looks like background noise. I'm not sure what that means.

[konstantin8818]

Board is equipped with socket for interlocks(two of them on the inverter). Is it mondatory those interlocks to be engaged for inverter operation?

[MattsAwesomeStuff]

Board is equipped with socket for interlocks(two of them on the inverter). Is it mondatory those interlocks to be engaged for inverter operation?

I believe so, yes, that's the point of them.

Does Damien's board have them also?

[Dylan Witt]

Board is equipped with socket for interlocks(two of them on the inverter). Is it mondatory those interlocks to be engaged for inverter operation?

I’m going to reinstall the connector and add electrical grease, then try again. This seems to be my only problem at the moment, other than tuning the motor

[konstantin8818]

Board is equipped with socket for interlocks(two of them on the inverter). Is it mondatory those interlocks to be engaged for inverter operation?

I believe so, yes, that's the point of them.

Does Damien's board have them also?

Well, this thread is about Damien's board, so my question was about it. It has socket, where interlock wires go, so I was wondering if board require those to be engaged to operate. For now I can't do anything about Inverter: job first, hobby second

[Dylan Witt]

I may have to check the interlocks and make sure they are all engaged

[Dylan Witt]

I updated the firmware, once again, and seems to have corrected all my problems, now I have a over current problem, smooth motor movement, but about five seconds of testing with software the motor wiring gets warm, and the inverter power wiring gets really warm, I would say a good hot summer day temperature, it warms my coolant up fast, software says motor phase one is 290amps, that’s just for five seconds of testing, what do I need to be changing? Uploading a video tomorrow to show what’s going on, low quality due to slow internet.

[konstantin8818]

Board is equipped with socket for interlocks(two of them on the inverter). Is it mondatory those interlocks to be engaged for inverter operation?

OK, finally got time to find schematics - this socket is not connected anywhere, so no need of it.
Also a little question: this is a photo of STM on that famous smoked board:

Two pins are bridged, is it OK, or I need to risk it with soldering iron to remove bridge?

[Isaac96]

If my pin1 reading is correct then you have bridged PA0 and PA1.

On the Rev2 board (Johannes' hardware) PA0 is the UVLO (or DESAT, can't tell which) and PA1 is the OC detect.
This board may or may not be the same. In any case bridges should usually come off anyways.

-Isaac

[Dylan Witt]

The same two pins on mine is bridged to, should I remove it before something happens? Remove the solder and see if that fixes any of my problems

[konstantin8818]

If my pin1 reading is correct then you have bridged PA0 and PA1.

On Damien's board PA1 is not used, and PA0 is MG2_UVLO_IN.

And we all know that Damien's board is operational, so I guess it is not a problem.

[Jack Bauer]

DO NOT remove the solder blob. I love the way people have such little faith in me. Those 2 pins are meant to be connected.

[konstantin8818]

DO NOT remove the solder blob. I love the way people have such little faith in me. Those 2 pins are meant to be connected.

I have a LOT of faith in you That is why I asked before acting. Just didn't want to disturb you with PM.

[Dylan Witt]

I wished someone had good parameters for the gen three inverter, I’ve depleted my 78 volt battery more than eight times trying to tune it to the Camry/Avalon transaxle, with little success on the spinning

[konstantin8818]

Got free time to figure out 35 pin plug wiring, and came to conclusion that this plate design is "no-go":

There is simply no room for IDC headers. So for 3D printing good design is outward facing plate, or flat plate if material is sturdy enough or it is milled from some hard plastic insteard of 3D printed.
Here is DXF drawing for flat plate for CNC milling. Keep in mind that recommended maximum plate thickness is no more than 4mm in area where 35way header is located(for correct installing).

gen3 header plate.zip

(9.82 KiB) Downloaded 87 times

[bobby_come_lately]

Got free time to figure out 35 pin plug wiring, and came to conclusion that this plate design is "no-go":
283.png
There is simply no room for IDC headers. So for 3D printing good design is outward facing plate, or flat plate if material is sturdy enough or it is milled from some hard plastic insteard of 3D printed.
Here is DXF drawing for flat plate for CNC milling. Keep in mind that recommended maximum plate thickness is no more than 4mm in area where 35way header is located(for correct installing).
gen3 header plate.zip

Did you see my designs over here Konstantin? This works well.
viewtopic.php?f=14&t=836

[konstantin8818]

Did you see my designs over here Konstantin? This works well.
viewtopic.php?f=14&t=836

Yes, your plate looks like my second design, when I added offset to add up integrity, because flat plate being bent by gasket . I have no 3D printer, yet I've got some 5 mm thick bakelite and textolite, and some instruments

[konstantin8818]

DO NOT remove the solder blob. I love the way people have such little faith in me. Those 2 pins are meant to be connected.

Will this bridge present on every board you ship? If yes, I'll add picture to wiki for other watchful customers

[Jack Bauer]

No its fixed now.

[Dylan Witt]

Does anyone know what everything means on the FOC web interface? Like the description of like tmpm I know this is temperature of the motor, but like the other stuff i can’t really figure out, this would help me tune the motor better. I have no ideal what it means.

[bobby_come_lately]

Does anyone know what everything means on the FOC web interface? Like the description of like tmpm I know this is temperature of the motor, but like the other stuff i can’t really figure out, this would help me tune the motor better. I have no ideal what it means.

Not watched the video yet but have you seen this on the Wiki? https://openinverter.org/wiki/Parameters

Between that and the (very short) FOC setup guide it seems to cover the key ones that you might need to change.

Are you getting a clean signal out of your resolver?