openinverter forum

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

Really appreciate this JB

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.

Bare pcbs have arrived. Available on the webshop for anyone interested.

Almost looks like one of those Lebowski cards now Nice work.
Just one thing, what about the resolver exciter?

I didn't bother with resolver on this revision. I actually want to run an induction motor with encoder. Next rev might have it.

Nice work, can you supply PCB+components as a DIY-kit?

To my surprise it works:)

Worth noting the drive transistor silkscreen is flipped.

Looking good. Did you allready spin something..?

GEN 2 MG2 current sensors seem to be 0v centered and react at 25mV/A.

Some videos for your viewing pleasure :

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?

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.

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 .
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 .

I'd try and find an old carbon pile battery tester like they used to use in garages.

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

That's great. What year are those Prius with this controller ?

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

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

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

Arber

In the gen 3 the fault signals are 5v when ok and 0v when faulted.

For anyone out there who doesnt think the Gen 2 Prius inverter can handle much current ....

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.

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