GS450H Motor Connectors

[dso]

Does anyone have the pinout for the Sumitomo 6189-1092 on the motor?

[arturk]

Here is what I have.
Please pay attention at Harness (Left) and Components (Right) sides.

[dso]

Awesome thank you.

[streber]

Does anyone know the part numbers for the harnesses that plug into the transmission and inverter?

I've figured out:
8216430040 is the harness from the battery to the inverter and is the two smaller white connectors.
8211130* appears to be the main engine harness and I think contains the connectors from the EV ECU and the Inverter (big plug), but can't confirm that or exactly which variant if it matters.
8212130D10 appears to be the ICE harness and does not appear to be the right one.

No clue for the rest of the transmission, although those seem much easier to replicate than the shielded stuff in the EV ECU <-> Inverter connection.

[RE3Rotor]

My 450h motor is missing the resolver plugs. Does this look correct to you folks? As for the four twisted pair, can I just wire them up using some CAT6 cables?

https://www.aliexpress.com/item/4000132 ... hweb201603_

[arturk]

My 450h motor is missing the resolver plugs. Does this look correct to you folks? As for the four twisted pair, can I just wire them up using some CAT6 cables?

https://www.aliexpress.com/item/4000132 ... hweb201603_

Yes, this is correct plug.
Keep in mind those wires have to be shielded, CAT6 shielded should work just fine. I would try to find thick 24AWG or 26AWG minimum.
I am using CAT8 S/FTP 24AWG with each pair is individually shielded.

[RE3Rotor]

Yes, this is correct plug.
Keep in mind those wires have to be shielded, CAT6 shielded should work just fine. I would try to find thick 24AWG or 26AWG minimum.
I am using CAT8 S/FTP 24AWG with each pair is individually shielded.

Awesome. I watched your video and those cables look great. I said CAT6 because I can easily get the scraps from work being in IT.

[xp677]

The 4 signals use CAN transceivers, so you should follow the requirements for CAN. Cat6 should be fine as each pair is individually screened, but who knows.

[RE3Rotor]

Does anyone have pinout for the resolver connections? Or all the different connections on the gearbox? Or if they can provide me screenshots of the section of the service manual, I can compile that together. I don't have all the wiring harness to go between the inverter and gearbox. I think it is valuable for those of us who needs to build a harness from scratch.

[Dilbert]

Here is an image of the connector, looking at the front of it.

[RE3Rotor]

Thank you.

[Dilbert]

The remaining two pins 4 & 8 are the motor temperature sensor, these don't connect to the inverter, they connect to the Vehicle ECU.

[RE3Rotor]

I thought I had it figured out but I don't. Do you happen to know what the two prefixes (M & G) on the resolver wiring denotes MG1 & MG2 respectively?

[Dilbert]

The wiring diagram is here https://openinverter.org/wiki/images/a/ab/Inverter.png

The pin numbers and signal named in the above diagram align with the earlier connector pin out I posted.

The ones starting with G are MG1 and M are MG2.

[RE3Rotor]

Luckily I have the harness from the gearbox to this oil pump controller. But do we have the diagram for the controller?

[xp677]

Luckily I have the harness from the gearbox to this oil pump controller. But do we have the diagram for the controller?

I know we covered it in the other thread, but just for those who see it here first, here's the diagram:

https://openinverter.org/wiki/File:Oilpump.png

For the wires to the pump itself (the red/white/black shielded cables for the motor, and the 5 feedback wires), just match the colours with your pump.

[Dilbert]

I measured the nominal value for the MG1 & MG2 thermistors and it came out @117K for an ambient temperature of 5-6C, which seems very high.

Has anyone else had a chance to measure the MG1 & MG2 thermistors?

[arturk]

I just checked mine and I am getting exactly the same results ~116K @ 6C
What the coincident that temperature in my garage is the same

[Dilbert]

It is hard to find data on the GS450H, but it looks like they are using they will use the same thermistor as the gen2 prius.

This NTC thermistor is 3900-3950K 47kohm!

[Dilbert]

Here is my function for calculating the temperature:-

float vcc = 5.0;
float adc_step = 3.3/1023.0;
float Rtop = 1800.0;
float Ro = 47000;
float To = 25+273;
float B = 3500;

float readThermistor(int adc){


float raw = adc;
float voltage = raw*adc_step;

float Rt = (voltage * Rtop)/(vcc-voltage);

float temp = (1/(1.0/To + (1.0/B)*log(Rt/Ro)))-273;

return temp;
}

[Dilbert]

If we want to get more information regarding the temperature rise on the motors, it might be worth changing the 1.8K pull-up to be something bigger.

With the 1.8K pull up the temp of the motor has to be > 90C before the ADC drops into range (<3.3V) where it can take a measurement.

I have verified the above calculation is correct, once the correct values for pull-up resistor is set.

[arturk]

Nice work!
Thanks for figuring it out.

[Dilbert]

Maybe a mod could move the above posts on the NTC to the vcu support thread

[PacEmaker]

If we want to get more information regarding the temperature rise on the motors, it might be worth changing the 1.8K pull-up to be something bigger.

With the 1.8K pull up the temp of the motor has to be > 90C before the ADC drops into range (<3.3V) where it can take a measurement.

I have verified the above calculation is correct, once the correct values for pull-up resistor is set.

Just to confirm - you're referring to R97 (MG1 temp) and R99 (MG2 temp) on Damien's V1 board?

[Dilbert]

R35 and R42 on the board I have (v2)