Toyota Prius Gen 2 Inverter Controller

[ZooKeeper]

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[ZooKeeper]

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[arber333]

Some testing on the 12v inverter inputs, current draw does not change with HV status or 12v on or not to I9 (Inverter logic power) under lid.

How high can you get itz working with HV? Maybe 320V?

A

[konstantin8818]

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?

If yourbattery is dead, and HV is still connected, 12V cirquit is live. DC-DC still provides needed 12v, but if you turn system off, then even the main board will not start as both Johu's and Damien's boards need 12V to operate.

[ZooKeeper]

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[konstantin8818]

According to this:

NODD is an output signal from DC-DC to HV ECU, and HV ECU switches converter on/off via VLO pin 5.

[ZooKeeper]

Yea, I see no reason based on my updated testing and documentation others have found, to connect anything to C5 other than 12v on pin #1. I will use a switched ignition source fused for 5A for C5-1 and I9-1 to power up the inverter/converter & DC-DC all in one circuit by jumping I9-1 to C5-1.

In point of fact, one could do the Board, C5-1 and I9-1 on the same "Ignition" circuit.

[ZooKeeper]

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[RetroZero]

Nice work, so what ever you throw at those Japanese boys, if it's above 150V input, they'll do the rest to provide 14,8v output?

[konstantin8818]

Nice work, so what ever you throw at those Japanese boys, if it's above 150V input, they'll do the rest to provide 14,8v output?

I guess, ZooKeeper was testing 12th pin "inverter capacitor voltage" output, as both Johu's and Damien's boards have got UDC input for voltage sensing, and they both limited up to 3.3V. So whatever voltage you use as your HV, if it below 330 volts, there is no need in voltage devider. Am I correct?

[RetroZero]

I had to look up UDC first to understand - it's the User Defined Code? Which is the algorithm for voltage sensing? My system is based on - 230v/65Ah (fully charged). EU 240v 16A house plug for overnight recharge compatible.
Ok, I understand now that sensing the "inverter capacitor voltage" is about monitoring output on pin 12. As the output voltage is around 1% (and not 10% as I incorrectly calculated it..) of High Voltage (battery voltage) it needs to be below 330V to not damage the 3.3V circuit. If not, a voltage devider circuit needs to be intalled in place of standard voltage sensing. Sound about right?

[SciroccoEV]

I had to look up UDC first to understand - it's the User Defined Code? Which is the algorithm for voltage sensing? My system is based on - 230v/65Ah (fully charged). EU 240v 16A house plug for overnight recharge compatible.
Ok, I understand now that sensing the "inverter capacitor voltage" is about monitoring output on pin 12. As the output voltage is around 1% (and not 10% as I incorrectly calculated it..) of High Voltage (battery voltage) it needs to be below 330V to not damage the 3.3V circuit. If not, a voltage devider circuit needs to be intalled in place of standard voltage sensing. Sound about right?

U is the symbol for voltage

[ZooKeeper]

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[ZooKeeper]

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[RetroZero]

Thanks, you answered half of what I was trying to get my non EE head around. After an hour or so of wiki and google:
1. Udc = dc bus voltage = high voltage in which the system is designed to operate - 202v for Prius Gen 2 (for example)
2. Udc requires monitoring for over and under voltage - example: once precharge is complete, Pin 12 is excited and Main Contacter is closed
3. Depending on parameters selected during set-up program, we program Pin 12 to switch off when over or undervoltage is detected in HV bus
4. To calculate this over or under voltage, we have a range between 0v3 -3v3 (0.3v - 3.3v), which is proportionate(1%) to HV bus (HV battery) = 30v - 330v
5. This calculation is what was being validated in the test?
6. If the system functions above 330v, a devider system must be put in place to not surpass(blow up) the 3v3 limit on Pin12
7. As long as the Udc stays within tolerences input during set-up, the DC/DC converter will also supply 14.2v to 12v circuit.

Sound right?

[ZooKeeper]

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[RetroZero]

Thanks ZooKeeper. I got 1 out of 7 right
It clears up alot for me. Basically we monitor output voltage on Pin 12, which is proportional to bus voltage (Udc)
The value can then be used for over/under voltage monitoring, and therefore set parameters for safety cut-offs?.
Also, the rev3 and Damien boards monitor voltage via pin 12, being connected to UDC pin on the board. As long as the voltage does not exceed 3.3v, there is no problem...That correct?

7. - no need for answering, I didn't understand the first part - the test had nothing to do with 12v battery circuit. I thought the voltage output on Pin 12 somehow had a proportional effect on charging 12v circuit.

[ZooKeeper]

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[ZooKeeper]

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[MattsAwesomeStuff]

So it's not quite linear, but it's within 10% (of 1% buss) at voltages above 90v. I can't imagine anyone's going to be running sub-100v.

Great work!

[RetroZero]

Yes, nice work. I suppose an algorithm/resistance could be created to make the output value more linear? That's the non EE speaking again.

[SciroccoEV]

Yes, nice work. I suppose an algorithm/resistance could be created to make the output value more linear? That's the non EE speaking again.

There is no real need to. The inverter only needs to know battery voltage in broad terms.

It is not the job of the inverter to protect the battery, that's the job of a BMS.

[arber333]

That is great! No expensive and sensitive opamp and isolated DCDC sinse everything is done by Toyota.

I think FOC needs some value to calculate amplitude? At least to start from still.

[mattndex@gmail.com]

More testing of the I-10 (12) "UDC"/"V" output, all measurements with internal 12v "ON" and "vdc":

I10-12 @ Buss vdc
0.533 @ 0.00
0.873 @ 56
0.990 @ 75
1.120 @ 96
1.453 @ 150
1.490 @ 156

From lack of things to do, I tried to find the most linear relationship between these points and this is what I came up with:

X = 162.97Y - 86.56 where X is Bus Vdc and Y is I10 voltage.

Error margin is manageable with given points, I'm hoping someone can introduce an off laying point for us to test the equation.

[arber333]

Hi

Forgive me for steering off topic for a bit.
I am looking to get a mating connector for my Prius Gen 2 compressor. Does anyone know what is the P/N for that connectopr and its opposite (male) part? TNX