Toyota Prius Gen 2 Inverter Controller

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Jack Bauer
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Toyota Prius Gen 2 Inverter Controller

Post by Jack Bauer »

While working on the blue pill for the Gen 3 I did some testing using a Gen 2 inverter so here is a little present. All fits on a 100mm x 100mm double sided pcb and all through hole:) Design files will be released soon.

EDIT (by Johannes, took the liberty): for more instructions please look here: https://openinverter.org/wiki/Toyota_Prius_Gen2_Board
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Re: Toyota Prius Gen 2 Inverter Controller

Post by Jack Bauer »

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Re: Toyota Prius Gen 2 Inverter Controller

Post by johnspark »

Really appreciate this JB
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Re: Toyota Prius Gen 2 Inverter Controller

Post by Dilbert »

Thanks JB. This looks great, plenty of gen 2 inverters out there for little money.

Does the resolver require external excitation?

Are the gen2 current semsors not bi polar (-3 to +3v), so would need level shift and divide by 2. Or possibly a 10k to the 3v3 rail and 10k to the current sensor.
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Re: Toyota Prius Gen 2 Inverter Controller

Post by Jack Bauer »

Bare pcbs have arrived. Available on the webshop for anyone interested.
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Re: Toyota Prius Gen 2 Inverter Controller

Post by johu »

Almost looks like one of those Lebowski cards now :) Nice work.
Just one thing, what about the resolver exciter?
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Re: Toyota Prius Gen 2 Inverter Controller

Post by Jack Bauer »

I didn't bother with resolver on this revision. I actually want to run an induction motor with encoder. Next rev might have it.
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Re: Toyota Prius Gen 2 Inverter Controller

Post by JaniK »

Nice work, can you supply PCB+components as a DIY-kit?
Any opinions are my own, unless stated otherwise. I take no responsibility if you follow my way of doing things and it doesn't work. Please double check with someone who knows what they are doing.
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Re: Toyota Prius Gen 2 Inverter Controller

Post by Jack Bauer »

To my surprise it works:)

Worth noting the drive transistor silkscreen is flipped.
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Re: Toyota Prius Gen 2 Inverter Controller

Post by JaniK »

Looking good. Did you allready spin something..? ;)
Any opinions are my own, unless stated otherwise. I take no responsibility if you follow my way of doing things and it doesn't work. Please double check with someone who knows what they are doing.
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Re: Toyota Prius Gen 2 Inverter Controller

Post by Jack Bauer »

GEN 2 MG2 current sensors seem to be 0v centered and react at 25mV/A.
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Re: Toyota Prius Gen 2 Inverter Controller

Post by Jack Bauer »

Some videos for your viewing pleasure :



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Re: Toyota Prius Gen 2 Inverter Controller

Post by MattsAwesomeStuff »

I'm having a great time watching this progress.

Can anyone dumb down for me what it means?

300-ish volts and 350 amps for a motor controller? (Or 600A if you can combine MG2 with MG1?).

I'm getting closer to the point where I'll be needing a controller, anyone have any advice on whether I should be pulling a Prius Gen2 or Gen3? Which is more likely to be something I could use, sooner?
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Re: Toyota Prius Gen 2 Inverter Controller

Post by Jack Bauer »

The Gen 2 can handle over 500v so yeah could be the bases for a nice little system which is what I'm trying to discover.

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Re: Toyota Prius Gen 2 Inverter Controller

Post by arber333 »

Hi Damien

Do you expect i can also do to Gen 3 inverter what you did to Gen2? I will use several 12V batteries to put power into transistor and use lots of H4 light bulbs in paralel to draw some 350A from there. I already have 100A load i used to test DCDC converter. Now i have to beef up the cables 8-) .
I will make a batch of H4 bulbs in pack of 5 for 25A and i can wire their contacts in paralel for 50A.
Do you maybe have another suggestion for the load, since it can get mighty bright here and i dont mean in my head :idea: .
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Re: Toyota Prius Gen 2 Inverter Controller

Post by Jack Bauer »

I'd try and find an old carbon pile battery tester like they used to use in garages.
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Re: Toyota Prius Gen 2 Inverter Controller

Post by MattsAwesomeStuff »

Arber - What's wrong with Damien's method, a big bar of steel? Go walk up to a chainlink fence and warm it up a little :p
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Re: Toyota Prius Gen 2 Inverter Controller

Post by mfox »

That's great. What year are those Prius with this controller ?
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Re: Toyota Prius Gen 2 Inverter Controller

Post by arber333 »

MattsAwesomeStuff wrote: Sat Sep 21, 2019 8:50 pm Arber - What's wrong with Damien's method, a big bar of steel? Go walk up to a chainlink fence and warm it up a little :p
Yes well i was trying to make more permanent solution. Maybe to use it also to drain and test cells. If i would have a stable load i could just measure time to empty and calculate exact capacity for tested cells. However i will search for carbon resistor load also...

Hm... What about 12V PTC resistance heaters :). I would have to have a lot of 500W ones but in the end i think i will need something of 5kW value.
https://www.ebay.co.uk/itm/Incubator-PT ... 2745199943
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Re: Toyota Prius Gen 2 Inverter Controller

Post by rikohm »

arber333 wrote: Sun Sep 22, 2019 10:53 am
MattsAwesomeStuff wrote: Sat Sep 21, 2019 8:50 pm Arber - What's wrong with Damien's method, a big bar of steel? Go walk up to a chainlink fence and warm it up a little :p
Yes well i was trying to make more permanent solution. Maybe to use it also to drain and test cells. If i would have a stable load i could just measure time to empty and calculate exact capacity for tested cells. However i will search for carbon resistor load also...

Hm... What about 12V PTC resistance heaters :). I would have to have a lot of 500W ones but in the end i think i will need something of 5kW value.
https://www.ebay.co.uk/itm/Incubator-PT ... 2745199943
There is "Dump load resistor" for smal windgenerators...
Both halogen and PTC will have high inrush current when cold. Might not be a problem but some thing to keep in mind.
I would go for Damiens solution but with a U or W shape in a (non melting) bucket of water.
With 5KW you have a steam sauna in notime
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Re: Toyota Prius Gen 2 Inverter Controller

Post by arber333 »

Damien did you find out what kind of signal is Fault, be it MG Fault or DCDC Fault? Is it Active high or Active low (open drain)?
I assume gen 3 has the same logic as Gen 2?

tnx

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Re: Toyota Prius Gen 2 Inverter Controller

Post by Jack Bauer »

In the gen 3 the fault signals are 5v when ok and 0v when faulted.
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Re: Toyota Prius Gen 2 Inverter Controller

Post by Jack Bauer »

For anyone out there who doesnt think the Gen 2 Prius inverter can handle much current ....
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Re: Toyota Prius Gen 2 Inverter Controller

Post by Jack Bauer »

210A RMS at 50Hz max current I could push through MG2 with the voltage available and risk of melting the Insight IMA motor stator I was using as a dummy load oil cooled in ATF. No cooling on the inverter. No shutdown or overcurrent trips. At 200A rms MG2 current sensors were swinging +/-7.5V perfect sine wave.
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Re: Toyota Prius Gen 2 Inverter Controller

Post by Jack Bauer »

Was also able to run an induction motor in full closed loop mode once I realised the stupid morons at Enova had wired the encoder cable screen to the motor casing :x
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