openinverter.org wiki - User contributions [en]

Toyota Prius Gen2 Inverter

2026-02-19T14:42:37Z

JeremyMakesThings: Added part number for ACinverter 6 pin logic connection

[[File:Prius Gen 2 inverter montage.jpg|alt=|thumb|Prius Gen 2 Inverter Montage]]
[[File:Prius Gen2 inverter internals.jpg|alt=|thumb|Internal look at the Prius Gen2 Inverter]]
[[File:Prius Gen 2 Layout.jpg|thumb]]

The Toyota Prius is a hybrid vehicle. Their inverters are suitable and attractive for DIY EVs because of:
* Large part availability, Priuses have been made in large numbers for 20 years and spares are inexpensive.
* High affordability. Prius inverters are available for around $150 from scrapyards everywhere.
* Durability. Toyota engineers appear to have made the inverters foolproof, many inputs and outputs gracefully handle fault conditions.
* Respectable performance. Rated for 50kW output, but tested to handle 600v, and [https://www.youtube.com/watch?v=y6mlXahM9B0 350+A for MG2 inverter, 250+A for MG1 inverter], 360kW total (480hp)
* Ease of re-purposing. Emulating the original ECU seems reasonably feasible.

The Gen2 Prius (2004-2009 model years) has a variety of useful components inside the inverter package:
* 2 high power inverters, for the 2 motors MG1 (starter) capable of handling 250 amps, and MG2 (drive motor) capable of handling 350 amps.
* A DC-DC converter to provide 12v and up to 100amps power supply to the automotive systems and accessories.
* A tertiary power inverter to run the A/C, CAN controlled via the "BEAN" (????) network
* A boost module to boost the 200v battery pack up to 500v, which looks to be able to function as a battery charger (wish list for future development)
* See this video for a thorough disassembly and explanation of the Gen2 Inverter (Timestamp 1:15:30): https://www.youtube.com/watch?v=Y7Vm-C4MsW8&t=4531
* See this video for a more brief explanation of the above noted disassembled Gen2 HV System Operation: https://www.youtube.com/watch?v=UxuqHcUbSQ0

Note that there is also a [[Toyota_Prius_Gen3_Board]] for the 2010-2015 model years.

== Replacement Controllers ==

Re-purposing a Prius Gen2 Inverter outside of a Prius is done simply with add-on controllers that replace the vehicle's wiring harness and ECU.

* [[Toyota Prius Gen2 EVBMW Throughhole Board]] - Details on the now-deprecated EVBMW "Blue Pill"-based easy-to-solder controller board, diagrams, instructions, pinouts, etc. Don't use this.
* [[Toyota Prius Gen2 Inverter Controller]] - Details on the newer OpenInverter controller board and kits to repurpose the Gen 2 Prius inverter. Use this.

== 32-pin Prius Inverter Pin mapping ==

Note: Wire colors on the male/female side of the 32-pin "i10" connector do not match. The inverter-side plug uses an almost unique color scheme, but the wiring harness side reuses many colors - unique only to a given shielded cable (of which there are 5), plus some extra unbundled wires. To save time chasing wires, you can find anything in the same bundle, and know the rest by noting which other colors are in that cable. There are also a few loose wires not bundled into a cable or shielded.

Note 2: The 12v supply rail for the "i9" connector also changes color at the wiring harness. The thicker blue loose wire is positive, the thick loose white-black wire is the ground.

Note 3: There is also an enclosure safety connector, this is the thin blue loose wire on the wiring harness.

[[File:Prius_Inverter_-_Pin_Numbering_2.jpg|thumb|500x500px|32-pin Prius Inverter Pin Numbering]]
[[File:Prius_Inverter_Wire_Colors_3.jpg|thumb|500x500px|32-pin Prius Inverter Pin Numbering]]
[[File:Prius_Inverter_Wire_Colors_2.jpg|thumb|500x500px|32-pin Prius Inverter Pin Numbering]]
[[File:Prius_Inverter_Wire_Colors_5.jpg|thumb|500x500px|32-pin Prius Harness Pin Numbering]]
[[File:Prius_Inverter_Wire_Colors_4.jpg|thumb|500x500px|32-pin Prius Harness Pin Numbering]]
[[File:Prius_Inverter_Wire_Colors_6.jpg|thumb|500x500px|32-pin Prius Inverter Colors]]
[[File:Prius_Inverter_Wire_Colors_7.jpg|thumb|500x500px|32-pin Prius Inverter Harness Connections]]
[[File:Prius_Inverter_Wire_Colors_8.jpg|thumb|500x500px|32-pin Prius Inverter i9 12v DC]]
[[File:Prius_Inverter_Wire_Colors_9.jpg|thumb|500x500px|32-pin Prius Inverter Harness Cables]]

{| class="wikitable"
|-
! Pin # !! Designation !! Description!!Wire Color
(Inverter Side)

(See pictures to the right)
!Wire Color
(Harness Side)
|-
|1||||vacant||
|
|-
|2||GIVA||MG1 Phase Current V||LightGreen
|White - Cable 1
|-
|3|| GIVB ||MG1 Phase Current V|| Purple-Red
|Black - Cable 1
|-
|4|| GUU ||MG1 PWM U - Speed Signal Wave||Blue
|Black - Cable 2
|-
|5|| GVU ||MG1 PWM V - Speed Signal Wave||Blue-Red
|Green - Cable 2
|-
|6|| GWU ||MG1 PWM W - Speed Signal Wave||Yellow
|Yellow - Cable 2
|-
|7|| MIVA || MG2 Phase Current V ||LightGreen-Black
|Green - Cable 3
|-
|8|| MIVB ||MG2 Phase Current V||Purple-Yellow
|White - Cable 3
|-
|9|| MUU ||MG2 PWM U - Speed Signal Wave|| Blue-Black
|Black - Cable 4
|-
|10|| MVU ||MG2 PWM V - Speed Signal Wave|| Blue-Yellow
|White - Cable 4
|-
|11|| MWU ||MG2 PWM W - Speed Signal Wave|| Yellow-Black
|Red - Cable 4
|-
|12|| VH ||Inverter Capacitor Voltage||Purple
|Yellow - Cable 3
|-
|13|| CPWM ||Boost converter PWM switch signal||Blue
|Black - Cable 5
|-
|14|| CT ||Boost converter temperature sensor||Green-Red
|Red - Cable 5
|-
|15|| VL ||Boost converter input voltage||Purple-White
|Yellow - Cable 5
|-
|16|| GINV || Inverter Ground ||Black-White
|Yellow - Cable 4
|-
|17||||vacant||
|
|-
|18|| GIWA ||MG1 Phase Current W||Grey
|Red - Cable 1
|-
|19|| GIWB || MG1 Phase Current W ||Grey-Black
|Green - Cable 1
|-
|20|| GSDN ||MG1 Shutdown||Brown-Black
|Red - Cable 2
|-
|21|| GIVT ||MG1 Inverter Temperature||Green-Black
|White - Cable 2
|-
|22|| GFIV ||MG1 Inverter Fail||White-Grey
|Grey
|-
|23|| MIWA ||MG2 Phase Current W||Grey-Green
|Red - Cable 3
|-
|24|| MIWB ||MG2 Phase Current W||Grey-Red
|Black - Cable 3
|-
|25|| MSDN ||MG2 Shutdown||Brown
|Green - Cable 4
|-
|26|| MIVT ||MG2 Inverter Temperature||Green
|Light Blue - Cable 4
|-
|27|| MFIV ||MG2 Inverter Fail||White
|Green
|-
|28|| OVH ||Overvoltage||Pink
|Brown
|-
|29|| CSDN ||Boost converter shutdown signal||Brown-White
|White - Cable 5
|-
|30|| FCV ||Boost converter fail signal||White-Red
|White
|-
|31|| OVL ||Boost converter over voltage signal||Pink-Blue
|Black
|-
|32|| GCNV ||Boost converter ground||Black-Red
|Green - Cable 5
|}

(Article continues below)

 
[[File:Toyota gen2 dimension.png|thumb]]

== DC-DC Converter ==
[[File:Prius Gen 2 inverter lower casing internals.png|thumb|300x300px|Prius gen 2 inverter lower casing internals]]
[[File:Gen2 Prius DC-DC Connections.jpg|thumb|Prius Gen2 DC-DC connections.|284x284px]]
[[File:Prius GEN 2 C 5 Connector Pinout.png|alt=|thumb|DC-DC converter "C 5" connector]]
The onboard DC-DC Converter is powered by the high voltage traction battery to supply 12v and up to 100A for low-voltage automotive components and 12 battery maintenance, equivalent to an alternator or generator. Direct control of the converter is simple, only one 12v wire connected to Pin#1 of connector "C5" is necessary to activate it, but a second input can be added at Pin#4, to enhance control.

All 6-pin connectors are Yazaki 7283-7062-40, including the resolver connections on the transaxle.

The 6-pin "C5" connector terminal positions and harness-side colors:

{| class="wikitable"
|-
! Pin # !! Designation !! Description !! Wire Color
|-
|1||IGCT|| 12v+ || Blue
|-
|2||ID1|| Not Needed || Purple
|-
|3||S||B+ (opt)|| White
|-
|4||NODD|| 0-5v+ ||Ppl/Gld
|-
|5||VLO||Not Needed||Blue
|-
|6|||| ||Vacant
|}

The case of the inverter must be vehicle ground (12v battery negative terminal), just as an alternator or generator would be.

With the HV bus energized and switched 12v applied to Pin#1 of "C5", the DC-DC will produce 13.2-15.2 Vdc on the large C6 single-conductor connector nearby, which is equivalent to a 12v alternator/generator positive terminal. Depending on voltage applied to pin 4 (if used), output can be tailored; when grounded, it will act as a "KILL" input and DC-DC output will drop to zero. No base load is required to produce voltage.

'''Note:''' The output at C6 (large grey connector) is not internally fused and not disabled unless power to Pin#1 of C5 is off, or Pin#4 is grounded, but the DC-DC converter can only produce output when the HV bus is energized.

Note on Limitations - The DC-DC system is not designed to charge up a low 12v battery and certainly not one that's completely dead, doing so can damage the inverter/converter. Pin#1 can be tied directly to the same ignition switch signal as the control board receives as this circuit draws only about 6.3mA.

 

== A/C Inverter ==
The onboard A/C inverter is powered by the high voltage traction battery to supply 3 phase power to the A/C pump. It's controlled by a propriety SPI like 12v interface.

The 6-pin "I11" connector (Yazaki PN: 7283-7064-40) terminal positions and inverter side colours:
[[File:Prius Gen2 A-C inverter control.gif|thumb]]
{| class="wikitable"
|-
! Pin # !! Designation !! Description !! Wire Color
|-
|1||GND|| GND || Black/White
|-
|2||TOECU(ITE)|| Data from inverter || Green/White
|-
|3||TOINV(ETI)||Data to inverter|| Yellow/White
|-
|4||CLK|| serial clock ||Brown/White
|-
|5||STB||chip select||Blue/White
|-
|6||IG|| 12v+||Red/White
|}
The CLK and ITE signals comes alive when supplying12V to IG and >40V to the main DC Power supply inlet and pull-up/pull-down connected to them(CLK and ITE). For the inverter to start you need higher voltage >200V to main DC Power supply inlet, STB to GND and send appropriate 10 byte messages to the inverter on ETI. For more information, logs, how to connect and example code to control See https://github.com/hakanrolsson/Prius-Gen2-A-C-compressor-inverter

== Buck/Boost Converter ==

The inverter also has an onboard buck/boost converter that - when needed - can boost the ~200v battery pack up to 600v to send to the motors, and buck down high voltage generated by the motors in regen mode to recharge the batteries. See 'Charging' section below for how the buck/boost converter has been used for AC charging. See link below for another method of controlling the buck/boost converter.

''Alternative Method:'' [https://openinverter.org/wiki/Operating_the_buck/boost_converter_for_a_low_voltage_CCS_charging_application Control of Prius Gen2 Buck/Boost converter for low voltage CCS charging]

== Inverter Cooling ==

The inverter is liquid cooled, coolant enters at the front and exits the rear of the inverter housing from the o-ring port connected to the Hybrid Synergy Drive (HSD) cooling system reservoir. Some type of circulating pump and radiator are needed to use Toyota inverters, many compact options are available.

== Wiring ==
Details on connectors and terminals have been posted on the IH8MUD website: https://www.ih8mud.com/tech/WireHarnessRepairParts.php

Alternatively, the Toyota wire repair book can be found here: https://www.toyota-tech.eu/wire_harness_rm/RM06H0E.pdf

Please use either or both of the above to identify the connector and terminal numbers needed for your project.
{| class="wikitable"
|+
!Connector
!Male
!Female
|-
|C5
|90980-10988
|90980-10987
|-
|B+ (DC-DC output)
|
|90980-11963
|-
|32-pin connector
|
|TE 1318747-1 (& 1123343-1 for pins)
|-
|28-pin connector (on inverter logic board)
|
|TE 1565380-1 (& 1123343-1 for pins)
|}

== Charging ==
The gen 2 can only charge in buck mode. So maximum charge voltage is limited to the rectified AC input. E.G. From a 230 VAC source the inverter can only charge up to around 320VDC

'''Relevant Parameters'''

Charge mode:Buck

Chargecur: 1.5

Chargekp 20

Chargeki: 10

Chargeflt 2 dig

Charge pwmmin: 10 (Change this to get equivalent to min battery voltage.)

udcswbuck: x (HV bus voltage at which point Ground signal is used to control AC and HV battery relays)

'''Relevant Pins'''

* CSDN (pin 29 on inverter)
** Shuts down high and low IGBTs when fed 12v, via 470R
** When CSDN is HIGH both IGBTs are OFF.
* CPWM(pin 31 on control board, 13 on inverter)
** Enables charge mode when fed 12v via 470R
** When CPWM is HIGH, the LOW side IGBT is on(shorts out battery), when CPWM is LOW the HIGH side IGBT is on.
* Forward and reverse (11 and 12 on control board)
** Both must be high to enable charging
* DCSW switch(15 in control board)
** Controls DC relay switch.

'''Physical setup'''

* 240v AC plugs into two MG1 phases, with a precharge resistor always on.
** Relay controlled by DCSW pin connected to ground side of relay signal wires.
* HV Battery connected with precharge resistor
** Relay controlled from DCSW pin connect to ground side of relay wires.
* CPWM to 12v via 470R resistor. Pulled high to when you want to charge
* CSDN pin to 12v via 470R resistor. Pulled high to when you want to charge
** CSDN pin also tied to DCSW signal pin, which pulls it down when precharge is complete.

'''Process'''

# Fwd and reverse signals high, relays open
# CPWM and CSDN pulled high via 470R .
# Connect AC input voltage with precharge
## DCSW will then close relays and pull down CSDN pin to activate charging.
# Activate buck on charger. (By manual web interface or does just having FWD and Reverse high activate this?
# To stop, can change chargecur to 0 or switch off inverter power.

== Offgrid AC Use ==

There has been moderate success using the Prius Gen 2 inverter to generate AC outlet voltages for offgrid use.

See: https://openinverter.org/forum/viewtopic.php?p=22886

See: https://github.com/jsphuebner/stm32-island

== External Links ==

https://www.youtube.com/watch?v=Xl87abBl9-A - Physical destructive teardown of the Gen2 inverter.
[[Category:Toyota]] [[Category:Inverter]]

Toyota Prius Gen2 Inverter Controller

2025-11-21T15:29:41Z

JeremyMakesThings: Edited CPWM instructions reguarding pull up resistor

The OpenInverter Prius Gen 2 Inverter Controller is an open-source board designed to repurpose the [[Toyota Prius Gen2 Inverter]] by replacing the essential components of the Prius wiring harness and electronics. It runs the OpenInverter.org software for vehicle control. It derives from the (now-deprecated) earlier Prius Gen 2 work done by Damien Maguire of EVBMW.com and is Damien's recommended replacement for the [[Toyota Prius Gen2 EVBMW Throughhole Board]].

== Purchase ==

2 versions are available, one mostly-assembled kit with all connectors and an enclosure, and a less expensive incomplete barebones kit:

Full kit: https://openinverter.org/shop/index.php?route=product/product&product_id=63

PCB-only kit: https://openinverter.org/shop/index.php?route=product/product&product_id=68

== Project ==

(Note: Links to Github/etc design files here?)

== Hardware Notes ==

(Note: this section is pretty sloppy, if you're looking to contribute, this would be a nice area to start)

'''Enclosure Details'''
{| class="wikitable"
|+The SMD board was designed to work the the following enclosure and connectors:
!Description
!Part Number
!Data Sheet
|-
|Cinch Header 12 + 20
|5810132011
|https://www.mouser.co.uk/datasheet/2/643/Bel_07192016_Modice%20ME-MX-1216545.pdf
|-
|Modice Enclosure
|5810130075
|https://www.mouser.co.uk/datasheet/2/643/dr-CCS-ICE-5810130065-75-1551287.pdf
|-
|Molex 12-Pin Connector
|0334721202
|https://www.mouser.co.uk/datasheet/2/276/0334721202_CRIMP_HOUSINGS-162938.pdf
|-
|Molex 20-Pin Connector
|0334722001
|https://www.mouser.co.uk/datasheet/2/276/0334722001_CRIMP_HOUSINGS-162940.pdf
|-
|WIFI Module
|MOD-WIFI-ESP8266
|https://www.ebay.co.uk/itm/194313893813?epid=2280174677&hash=item2d3e02b7b5:g:v-MAAOSw4ulhJ1wg
|-
|WIFI Pins
|10-way IDC Box Header Connector
|https://www.ebay.co.uk/itm/153727472406
|}
Pin Mapping - Note : Smaller 12-pin socket is the interface to the inverter & 20-pin to the motor
[[File:32 Pin Main Inverter connector .png|thumb|32 Pin Main white connector Gen 2 Inverter emplacement]]
'''20 - Pin socket'''

Pin#01 - ENC_B/S3

Pin#02 - S1S4

Pin#03 - ENC_A/S2

Pin#04 - R1

Pin#05 - R2

Pin#06 - 5V

Pin#07 - THROTTLE 1

Pin#08 - THROTTLE 2
[[File:VCU to Prius Gen2 v1.1.png|alt=|thumb|VCU to Prius Gen2 wiring v1.1]]
Pin#09 - START_IN (12V) '''Push button type switch - not a permanent 12v input'''

Pin#10 - BRAKE_IN (12V) '''Push button type switch - not a permanent 12v input'''
[[File:Adapter board pin outs.png|thumb|Adapter Board Pin out locations]]
Pin#11 - FORWARD_IN (12V) '''(1, 2 or 3 way switch) Do not connect permanently - selected AFTER START'''

Pin#12 - REVERSE_IN (12V) '''(1, 2 or 3 way switch) Do not connect permanently - selected AFTER START'''

Pin#13 - Motor Temp -

Pin#14 - Motor Temp +

Pin#15 - DC (HV) Switch Control (Ground signal)

Pin#16 - Pre-ChARGE Control (Ground signal)

Pin#17 - CAN L

Pin#18 - CAN H

Pin#19 - Ground

Pin#20 - 12V "Ignition"

'''12 - Pin socket ( starts at pin number #21) - Corresponding pin on Main White 32 pin Inverter connector is in brackets.'''

Pin#21 - GIVA (2)

Pin#22 - MIVA (7)

Pin#23 - GIWA (18)

Pin#24 - MIWA (23)

Pin#25 - VH (12)

Pin#26 - MIVT (26)

Pin#27 - MFIV (27)

'''Pin#28 - MUU (9)'''

'''Pin#29 - MVU (10)'''

'''Pin#30 - MWU (11)'''

'''Pin#31 - CPWM (13)'''

Pin#32 - GINV/GCNV (16/32)

Connect MSDN Pin#25 in inverter (not 25 on controller) permanently to 12V to enable the MG2 Inverter (can be tied to same 12v source as "I9")

Connect CPWM to 12V via a 470 Ohm resistor to enable the Buck/Boost convert if using the DC/DC converter or charge mode.

Connect the 2-pole white power connector ("I9") inside inverter to 12V and Ground to power up inverter electronics.

Make sure to connect Pin #32 and #16 GINV/GCNV to vehicle ground.

'''<big>Initial Set up</big>'''

'''Step 1''' : Solder relevant (and included) connector pins to the Adapter Board

'''Step 2''' : Plug in Wifi Adapter and connect ONLY Pin#19 - GROUND and Pin#20 - 12 Volts power supply

Confirm PWR LED lights up along with WIFI LED. Confirm ALIVE LED flashes.

'''Step 3''' : Connect computer/laptop to the wifi network (Example - Inverter 7)

'''Step 4''' : Go to browser toolbar and type in 192.168.4.1 + Enter. (allow pop ups/Trusted site). Confirm Web based Interface appears and list of parameters appear.

If parameters appear, you are now connected to the Adapter board and the Web based Interface - Congratulations - You are now in the Matrix !

'''Step 5''' : Wire up '''12 Pin SMD''' board connector to corresponding '''32 Pin Inverter''' connector, permanent 12 volt supply to Pin #25 (MSDN) of Inverter, and 12V and Ground to 2-pole Inverter connector (next to main 32 pin white connector)

'''Step 6''' : Connect fused 12 volt and Ground to HV Inputs (battery), along with 55 watt light bulb in series (resistor) on the Positive line

'''Step 7''' : Connect fused 12 volt power supply for SMD board , Pin #25, and Inverter 2-pole connector - You are now set up for basic Open Loop motor spinning!

'''Step 8''' : Connect 21 watt light bulbs in Delta connection to the 3 PWM outputs in Inverter ('''no motor''') - https://openinverter.org/forum/download/file.php?id=4273&mode=view

'''Step 9''' : Web Interface Basic parameters ( stm32_sine. bin) set up - to confirm PWM outputs : Full boost (curki= 20000 min) with 12v supply, default forward, ampnom @ 70%, and fslipspnt @1 Hz. Select - "'''Start Inverter in Manual Mode'''" Confirm flashing lights.

'''Step 10''' : Connect motor phase wires to inverter PWM outputs. Repeat Step 9 and change "fslipspnt" by 1 unit at a time, until motor spins smoothly. (I noticed Light bulb resistor on HV line lights up when no spinning) along with high current values. Once you have the motor spinning, continue to increase the "fslipspnt" value whilst monitoring the current (ampmeter on PWM output wire) You will also notice the light bulb starting to fade untill there is no more light. Optimal motor spinning in Open Loop Mode ! (these values are related to a 12 volt HV supply - re using these parameters is still to be verified at greater supply voltages)

== Software ==

The Control Board runs Open Inverter software. A set of known-good default inverter parameters can be found here: https://openinverter.org/wiki/Configuration_Files#Toyota_Prius_Gen2_Inverter

'''''Do NOT program a deadtime value over 0 for the Gen2 inverter.''''' It only uses 1 PWM per phase and the inverter itself generates a low-side and high-side signal WITH deadtime.
[[Category:Toyota]] [[Category:Inverter]]