Prius Gen2 adapter board development thread

[ZooKeeper]

Haha, no matter what brilliant things you do, it's always the stupid things that stick

Many, author included, find that the most is learned from mistakes. I think it is time for me to stop working toward my Phd

[Richerson]

Hi Guys, I have a gen2 inverter. I'm going to drive a hvh250 remy core with it, is it possible to charge a 350v pack with this? In boost mode would i have to make any hardware changes or is it controlled in the software? Thanks in advance.

[johu]

Hi Guys, I have a gen2 inverter. I'm going to drive a hvh250 remy core with it, is it possible to charge a 350v pack with this? In boost mode would i have to make any hardware changes or is it controlled in the software? Thanks in advance.

It is possible if your rectified mains is > 400V. In other words only with rectified 380/400V 3-phase. Thats because in direction inverter -> battery it is a buck converter, not boost.
The DC/DC converter is not going to work at 350V if I remember correctly

[arber333]

The DC/DC converter is not going to work at 350V if I remember correctly

If you look at the thread about yaris inverter somewhere here, dcdc can be tweaked for higher voltage too... You may experiment with it some... Supposedly some resistors need replacing and such...

[Pikoko]

So i recently came across a gen 2 thats been sitting on a body shop lot that i have been in the process of pulling apart (perk of the job). I went ahead and pulled the factory service information for the inverter and made a nice pinout diagram and figured i would share it.
Im hoping to get a blue pill programmed and see if i can get this the to power up. still working on getting the transmission but i did pull the MG2 stator and rotor.

This is for a 2007 prius.
Note that the internal pinouts are the pinouts on each component. External is for the 32 pin connector on the inside of the inverter which connects to the vehicle. note that the DC-DC converter does not have the internal pinout as i haven't pinned it out.

[RetroZero]

That's awesome thanks. Might have to go in the wiki link...

[Pikoko]

That's what I was hoping. I've been trying to make it sortable in excel but it doesnt like the wire color columns.

Is there a github repo with the board design files and the current test firmware? I know how to work with kicad and could layout the board in it if yall are still looking for someone to do that. Also it looks like mouser offers a library for the modice connector.

[MattsAwesomeStuff]

made a nice pinout diagram and figured i would share it.

Great stuff! I'll see if I can get around to adding it to the wiki later today.

I'm not sure how to do color coding the way you've done it, using wiki markup, I'll have to do some studying.

[MattsAwesomeStuff]

Is there a github repo with the board design files and the current test firmware?

Just in case you're confused about the current state of affairs. There are two separate Prius Gen 2 projects.

1 - Damien's design using through-hole components and the Blue Pill.

2 - Johannes' adapter board.

Damien's design is a dead end. A year ago, his old PCB source charged absurd rates for component placing, and he figured SMT was intimidating for beginners, so he chose the Blue Pill and through-hole components so that anyone could build the board themselves. His new PCB source (JLPCB) is so much cheaper for components (if you can rework your design to use parts from their inventory) and placing that you can't even save money by building the board yourself. On his eventual to-do list was for him to redo both the Gen 2 and Gen 3 (SMT) control boards. At the time, a couple other forum members had put a lot of effort into hijacking the Gen 3 boost converter, so Damien built that one first. He has not yet redesigned the Gen 2, and, and, might not, but the Blue Pill is a bit of a hack and is a dead-end regardless. It's also rather limited, doesn't have proper circuitry for the current sensors, can't do two motors at once, can't do charging. It was a proof of concept. The only people who'll use it are those of us using it right now.

Johannes *just* finished his design, I don't think he's even received the boards from the PCB manufacturer yet to be able to test them. That's this thread. It started out with him thinking he could use one of his generic Open Inverter control boards and an add-on adapter, but has since become its own standalone board. The only thing it doesn't do is charging. We don't know pricing yet.

[Pikoko]

made a nice pinout diagram and figured i would share it.

Great stuff! I'll see if I can get around to adding it to the wiki later today.

I'm not sure how to do color coding the way you've done it, using wiki markup, I'll have to do some studying.

I'm working on it right now. I'll post the code when its done

[Pikoko]

Is there a github repo with the board design files and the current test firmware?

Just in case you're confused about the current state of affairs. There are two separate Prius Gen 2 projects.

1 - Damien's design using through-hole components and the Blue Pill.

2 - Johannes' adapter board.

Damien's design is a dead end. A year ago, his old PCB source charged absurd rates for component placing, and he figured SMT was intimidating for beginners, so he chose the Blue Pill and through-hole components so that anyone could build the board themselves. His new PCB source (JLPCB) is so much cheaper for components (if you can rework your design to use parts from their inventory) and placing that you can't even save money by building the board yourself. On his eventual to-do list was for him to redo both the Gen 2 and Gen 3 (SMT) control boards. At the time, a couple other forum members had put a lot of effort into hijacking the Gen 3 boost converter, so Damien built that one first. He has not yet redesigned the Gen 2, and, and, might not, but the Blue Pill is a bit of a hack and is a dead-end regardless. It's also rather limited, doesn't have proper circuitry for the current sensors, can't do two motors at once, can't do charging. It was a proof of concept. The only people who'll use it are those of us using it right now.

Johannes *just* finished his design, I don't think he's even received the boards from the PCB manufacturer yet to be able to test them. That's this thread. It started out with him thinking he could use one of his generic Open Inverter control boards and an add-on adapter, but has since become its own standalone board. The only thing it doesn't do is charging. We don't know pricing yet.

Gotcha. Well good news for me is im not afraid of of SMD components. Do you want me to PM you the code for the inverter table?

[Stephen Darbey]

Hi Guys.

I have been reading all this thread and scratching my head on why there are two projects that seemingly do the same thing. Thanks Matt for clarifying. I purchased one of Damien's pcbs months ago and the BOM to go with it. My plan was to assemble when I got some time. I might as well complete just for the education alone. I find as you assemble and solder, you learn what the circuit is doing as oppose to blindly blobbing components with lead.
I also have two gen2 inverters so, maybe some day I will have one of each.
Regards
Stephen

[MattsAwesomeStuff]

Gotcha. Well good news for me is im not afraid of of SMD components. Do you want me to PM you the code for the inverter table?

Nope, I always edit the code directly in wiki, so, I'll pick it up as soon as I see it.

Soon it will probably be time to fork the Prius Gen 2 page into 3 pieces. One for the Gen 2 itself with all that info, then one for Damien's Blue Pill (mostly just an archive, as it's a dead end and a small group of us only that ever need to use that info), and then another for Johannes' adapter board. Alternatively, Damien and Johannes' boards will have small enough info we might get away with just a subsection on them, but, wiring and pinouts on Damien's alone is a hefty portion of the page.

SMD might not be an issue for you, but, Damien never even designed a Prius Gen 2 board with SMD. The Gen 3 board was a DIY SMD, but now that one is obsolete too, he's redesigned it using JLPCB's more limited inventory, pre-placed parts, and built it right into the same form factor as Toyota's factory board. Rip out the Toyota one, screw the new one down in its place. So functionally there's no DIY SMD skills required for an Prius project right now, unless there's some early Gen 3 guys around.

[MattsAwesomeStuff]

I have been reading all this thread and scratching my head on why there are two projects that seemingly do the same thing.

It's more confusing when you realize that Damien uses Johannes' software and some of the hardware designs, and that all of this is sort of done under the Open Inverter umbrella despite Johannes' Open Inverter hardware also being his own.

If there aren't multiple projects of people pursuing what they think works best, it wouldn't be a real open source project :p

[johu]

The only thing it doesn't do is charging. We don't know pricing yet.

Thanks for the clarification. Just one small correction: it will support charging.
Pricing will be around 300€ including the ModICE enclosure and connectors.

[MattsAwesomeStuff]

Thanks for the clarification. Just one small correction: it will support charging.

Oops. Right. It doesn't support using the boost converter to boost while driving.

Will it support US-style 120v charging or just 240v?

[Pikoko]

Nope, I always edit the code directly in wiki, so, I'll pick it up as soon as I see it.

What i ment was i converted the excel tables to wikimedia tables.
This is the table for the inverter

Code: Select all

{| class="wikitable"
! colspan="11" style="text-align: center; font-weight:bold;" | Inverter
|-
| colspan="4" style="text-align: center; font-weight:bold;" | Internal
| colspan="4" style="text-align: center; font-weight:bold;" | External
| colspan="3" style="text-align: center; font-weight:bold;" | Notes
|-
| style="text-align: center;" | PIN #
| colspan="2" style="text-align: center;" | COLOR
| style="text-align: center;" | Function
| style="text-align: center;" | PIN #
| colspan="2" style="text-align: center;" | Color
| style="text-align: center;" | Shield
| style="text-align: center;" | Notes
| style="text-align: center;" | Direction
| style="text-align: center;" | Grouping
|-
| style="text-align: center;" | 1
| colspan="2" style="text-align: center; background-color:#cd9934;" | BRN
| style="text-align: center;" | MSDN
| style="text-align: center;" | 25
| colspan="2" style="text-align: center; background-color:#32cb00;" | GRN
| style="text-align: center;" | 4
| MG2 Shutdown
| style="text-align: center;" | INPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 2
| colspan="2" style="text-align: center;" | WHT
| style="text-align: center;" | MFIV
| style="text-align: center;" | 27
| colspan="2" style="text-align: center; background-color:#32cb00;" | GRN
| style="text-align: center;" | 
| MG2 inverter fail
| style="text-align: center;" | OUTPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 3
| colspan="2" style="text-align: center; background-color:#32cb00;" | GRN
| style="text-align: center;" | MIVT
| style="text-align: center;" | 26
| colspan="2" style="text-align: center; background-color:#3166ff; color:#ffffff;" | BLU
| style="text-align: center;" | 4
| MG2 inverter temp
| style="text-align: center;" | OUTPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 4
| style="text-align: center; background-color:#cd9934;" | BRN
| style="text-align: center; background-color:#000000; color:#ffffff;" | BLK
| style="text-align: center;" | GSDN
| style="text-align: center;" | 20
| colspan="2" style="text-align: center; background-color:#fe0000; color:#ffffff;" | RED
| style="text-align: center;" | 1
| MG1 shutdown
| style="text-align: center;" | INPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 5
| style="text-align: center;" | WHT
| style="text-align: center; background-color:#32cb00;" | GRN
| style="text-align: center;" | GFIV
| style="text-align: center;" | 22
| colspan="2" style="text-align: center; background-color:#c0c0c0;" | GRY
| style="text-align: center;" | 4
| MG1 inverter fail
| style="text-align: center;" | OUTPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 6
| style="text-align: center; background-color:#32cb00;" | GRN
| style="text-align: center; background-color:#333333; color:#ffffff;" | BLK
| style="text-align: center;" | GIVT
| style="text-align: center;" | 21
| colspan="2" style="text-align: center;" | WHT
| style="text-align: center;" | 1
| MG1 inverter temp
| style="text-align: center;" | OUTPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 7
| colspan="2" style="text-align: center; background-color:#3166ff; color:#ffffff;" | BLU
| style="text-align: center;" | GUU
| style="text-align: center;" | 4
| colspan="2" style="text-align: center; background-color:#333333; color:#ffffff;" | BLK
| style="text-align: center;" | 1
| MG1 phase U PWM
| style="text-align: center;" | INPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 8
| style="text-align: center; background-color:#3166ff; color:#ffffff;" | BLU
| style="text-align: center; background-color:#fe0000; color:#ffffff;" | RED
| style="text-align: center;" | GVU
| style="text-align: center;" | 5
| colspan="2" style="text-align: center; background-color:#32cb00;" | GRN
| style="text-align: center;" | 1
| MG1 phase V PWM
| style="text-align: center;" | INPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 9
| colspan="2" style="text-align: center; background-color:#fffe65;" | YEL
| style="text-align: center;" | GWU
| style="text-align: center;" | 6
| colspan="2" style="text-align: center; background-color:#fffe65;" | YEL
| style="text-align: center;" | 1
| MG1 phase W PWM
| style="text-align: center;" | INPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 10
| colspan="2" style="text-align: center; background-color:#c0c0c0;" | GRY
| style="text-align: center;" | GIWA
| style="text-align: center;" | 18
| colspan="2" style="text-align: center; background-color:#fe0000; color:#ffffff;" | RED
| style="text-align: center;" | 3
| MG1 phase current W
| style="text-align: center;" | OUPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 11
| style="text-align: center; background-color:#c0c0c0;" | GRY
| style="text-align: center; background-color:#333333; color:#ffffff;" | BLK
| style="text-align: center;" | GIWB
| style="text-align: center;" | 19
| colspan="2" style="text-align: center; background-color:#32cb00;" | GRN
| style="text-align: center;" | 3
| MG1 phase current W
| style="text-align: center;" | OUTPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 12
| colspan="2" style="text-align: center; background-color:#9aff99;" | LT GRN
| style="text-align: center;" | GIVA
| style="text-align: center;" | 2
| colspan="2" style="text-align: center;" | WHT
| style="text-align: center;" | 3
| MG1 phase current V
| style="text-align: center;" | OUTPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 13
| style="text-align: center; background-color:#6665cd; color:#ffffff;" | VIO
| style="text-align: center; background-color:#fe0000; color:#ffffff;" | RED
| style="text-align: center;" | GIVB
| style="text-align: center;" | 3
| colspan="2" style="text-align: center; background-color:#333333; color:#ffffff;" | BLK
| style="text-align: center;" | 3
| MG1 phase current V
| style="text-align: center;" | OUTPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 14
| colspan="2" style="text-align: center; background-color:#fe0000; color:#ffffff;" | RED
| style="text-align: center;" | IGCT
| style="text-align: center;" | 1
| colspan="2" style="text-align: center; background-color:#3166ff; color:#ffffff;" | BLU
| style="text-align: center;" | 
| 2 pin connector/12v IG
| style="text-align: center;" | INPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 15
| colspan="2" style="text-align: center; background-color:#333333; color:#ffffff;" | BLK
| style="text-align: center;" | GND
| style="text-align: center;" | 2
| style="text-align: center;" | WHT
| style="text-align: center; background-color:#333333; color:#ffffff;" | BLK
| style="text-align: center;" | 
| 2 pin connector
| style="text-align: center;" | INPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 16
| colspan="2" style="text-align: center; background-color:#ffccc9;" | PNK
| style="text-align: center;" | OVH
| style="text-align: center;" | 28
| colspan="2" style="text-align: center; background-color:#cd9934;" | BRN
| style="text-align: center;" | 
| Over voltage
| style="text-align: center;" | OUTPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 17
| colspan="2" style="text-align: center; background-color:#6665cd; color:#ffffff;" | VIO
| style="text-align: center;" | VH
| style="text-align: center;" | 12
| colspan="2" style="text-align: center; background-color:#fffe65;" | YEL
| style="text-align: center;" | 2
| Inverter cap voltage
| style="text-align: center;" | OUTPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 18
| style="text-align: center; background-color:#3166ff; color:#ffffff;" | BLU
| style="text-align: center; background-color:#333333; color:#ffffff;" | BLK
| style="text-align: center;" | MUU
| style="text-align: center;" | 9
| colspan="2" style="text-align: center; background-color:#333333; color:#ffffff;" | BLK
| style="text-align: center;" | 4
| MG2 phase U PWM
| style="text-align: center;" | INPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 19
| style="text-align: center; background-color:#3166ff; color:#ffffff;" | BLU
| style="text-align: center; background-color:#fffe65;" | YEL
| style="text-align: center;" | MVU
| style="text-align: center;" | 10
| colspan="2" style="text-align: center;" | WHT
| style="text-align: center;" | 4
| MG2 pahse V PWM
| style="text-align: center;" | INPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 20
| style="text-align: center; background-color:#fffe65;" | YEL
| style="text-align: center; background-color:#333333; color:#ffffff;" | BLK
| style="text-align: center;" | MWU
| style="text-align: center;" | 11
| colspan="2" style="text-align: center; background-color:#fe0000; color:#ffffff;" | RED
| style="text-align: center;" | 4
| MG2 phase W PWM
| style="text-align: center;" | INPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 21
| colspan="2" style="text-align: center;" | N/A
| style="text-align: center;" | 
| style="text-align: center;" | 
| colspan="2" style="text-align: center;" | N/A
| style="text-align: center;" | 
| 
| style="text-align: center;" | 
| style="text-align: center;" | 
|-
| style="text-align: center;" | 22
| colspan="2" style="text-align: center;" | N/A
| style="text-align: center;" | 
| style="text-align: center;" | 
| colspan="2" style="text-align: center;" | N/A
| style="text-align: center;" | 
| 
| style="text-align: center;" | 
| style="text-align: center;" | 
|-
| style="text-align: center;" | 23
| colspan="2" style="text-align: center;" | N/A
| style="text-align: center;" | 
| style="text-align: center;" | 
| colspan="2" style="text-align: center;" | N/A
| style="text-align: center;" | 
| 
| style="text-align: center;" | 
| style="text-align: center;" | 
|-
| style="text-align: center;" | 24
| style="text-align: center; background-color:#6665cd; color:#ffffff;" | VIO
| style="text-align: center; background-color:#fffe65;" | YEL
| style="text-align: center;" | MIVB
| style="text-align: center;" | 8
| colspan="2" style="text-align: center;" | WHT
| style="text-align: center;" | 2
| MG2 phase current V
| style="text-align: center;" | OUTPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 25
| style="text-align: center; background-color:#9aff99;" | LT GRN
| style="text-align: center; background-color:#333333; color:#ffffff;" | BLK
| style="text-align: center;" | MIVA
| style="text-align: center;" | 7
| colspan="2" style="text-align: center; background-color:#32cb00;" | GRN
| style="text-align: center;" | 2
| MG2 phase current V
| style="text-align: center;" | OUTPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 26
| style="text-align: center; background-color:#c0c0c0;" | GRY
| style="text-align: center; background-color:#fe0000; color:#ffffff;" | RED
| style="text-align: center;" | MIWB
| style="text-align: center;" | 24
| colspan="2" style="text-align: center; background-color:#333333; color:#ffffff;" | BLK
| style="text-align: center;" | 2
| MG2 phase current W
| style="text-align: center;" | OUTPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 27
| style="text-align: center; background-color:#c0c0c0;" | GRY
| style="text-align: center; background-color:#32cb00;" | GRN
| style="text-align: center;" | MIWA
| style="text-align: center;" | 23
| colspan="2" style="text-align: center; background-color:#fe0000; color:#ffffff;" | RED
| style="text-align: center;" | 2
| MG2 phase current W
| style="text-align: center;" | OUTPUT
| style="text-align: center;" | 
|-
| style="text-align: center;" | 28
| style="text-align: center; background-color:#333333; color:#ffffff;" | BLK
| style="text-align: center;" | WHT
| style="text-align: center;" | GINV
| style="text-align: center;" | 16
| colspan="2" style="text-align: center; background-color:#fffe65;" | YEL
| style="text-align: center;" | 4
| Inverter ground
| style="text-align: center;" | INPUT
| style="text-align: center;" | 
|}

[Pikoko]

I just took a brief look at the schematic. The MCU that Johu is using is the same MCU that is on the Blue pill which is a stm32F103R. So while yes the Damian's build is older and through hole the MCU's are the same.

[johu]

Well sortof, it is the STM32F103C8T6 on the Blue Pill (as opposed to F103RBT6) which is a 48 pin part with only 64k flash. It mostly comes with 128k flash anyway, but those that do not will not be able to store parameters and CAN mappings. Also it seems the Blue Pill has either a layout problem or a rip off silicon, as the PWM shuts itself down by coupling over to the break pin. Found a couple of other issues like lack of 5V tolerant pins. All in all the Blue Pill is not the way forward.

[Pikoko]

Ah 10-4. well i found a cute little dev board https://www.mpja.com/ARM-Cortex-Develop ... 2691%20MP/ cost about $13 US shipped which isnt to bad.

[RetroZero]

Sorry if I am getting ahead of myself.... New adapter board will consist of 12 + 20 configuration located inside a ModICE enclosure, yes?
I am looking at Mouser and Farnell to order the matching connectors and female pin connectors. Can anyone confirm the connector references, so I can start doing some ordering? Thanks.

[johu]

If you look here, connectors and pins are linked at the bottom: https://www.digikey.de/product-detail/d ... ND/6199347

Like said, it will all be part of the kit!

[johu]

JLC dispatched the boards today

[RetroZero]

Excellent News! I am so sorry for not going back to page 1 and double checking your list proposed for the kit. I will go stay in my corner and hide away....maybe play with a Gen 2 planet gear

[Alibro]

While I'm patiently (NOT) waiting for the boards to wing their way to Johannas for testing I have a stupid beginners question.
I recently got my hands on a GEN2 inverter for the princely sum of £75 delivered (it was too cheap to say no) and am trying to plan the parts required to build an EV. From what I've read and seen this inverter should be powerful enough to do my job as I'm not interested in anything much more than 80kW. The car hasn't been bought yet but will likely be FWD or possibly even 4WD.
Would a Nissan Leaf motor be a suitable match or can anyone suggest another motor that might do the job?
Thanks in advance