Toyota Prius Gen2 Board: Difference between revisions

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[[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]]
The Toyota Prius is a hybrid vehicle. Their inverters are suitable and attractive for DIY EVs because of:
* Large part availability, Prii 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:
This page is now deprecated in favor of the following new pages:
* 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


== 32-pin Prius Inverter Pin mapping ==
* [[Toyota Prius Gen2 Inverter]] - General knowledge about the Toyota inverter itself, how it functions, pinouts, etc.
[[File:Prius Inverter - Pin Numbering.png|thumb|500x500px|32-pin Prius Inverter Pin Numbering]]
* [[Toyota Prius Gen2 EVBMW Throughhole Board]] - Details on the now-deprecated EVBMW "Blue Pill"-based easy-to-solder controller board, diagrams, instructions, pinouts, etc.
[[File:Prius_Inverter_Wire_Colors_3.jpg|thumb|500x500px|32-pin Prius Inverter Pin Numbering]]
* [[Toyota Prius Gen2 Inverter Controller]] - Details on the newer OpenInverter controller board and kits to repurpose the Gen 2 Prius inverter.
[[File:Prius_Inverter_Wire_Colors_2.jpg|thumb|500x500px|32-pin Prius Inverter Pin Numbering]]
[[Category:OEM]] [[Category:OpenInverter]] [[Category:Toyota]] [[Category:Obsolete]]
 
{| 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
|-
|3|| GIVB ||MG1 Phase Current V|| Purple-Red
|Black
|-
|4|| GUU ||MG1 PWM U - Speed Signal Wave||Blue
|Black
|-
|5|| GVU ||MG1 PWM V - Speed Signal Wave||Blue-Red
|Green
|-
|6|| GWU ||MG1 PWM W - Speed Signal Wave||Yellow
|Yellow
|-
|7|| MIVA || MG2 Phase Current V ||LIghtGreen-Black
|Green
|-
|8|| MIVB ||MG2 Phase Current V||Purple-Yellow
|White
|-
|9|| MUU ||MG2 PWM U - Speed Signal Wave|| Blue-Black
|Black
|-
|10|| MVU ||MG2 PWM V - Speed SIgnal Wave|| Blue-Yellow
|White
|-
|11|| MWU ||MG2 PWM W - Speed Signal Wave|| Yellow-Black
|Red
|-
|12|| VH ||Inverter Capacitor Voltage||Purple
|Yellow
|-
|13|| CPWM ||Boost converter PWM switch signal||Blue
|Black
|-
|14|| GSDN ||MG1 Shutdown||Green-Red
|Red
|-
|15|| VL ||Boost converter input voltage||Purple-White
|Yellow
|-
|16|| GINV || Inverter Ground ||Black-White
|Yellow
|-
|17||||vacant||
|
|-
|18|| GIWA ||MG1 Phase Current W||Grey
|Red
|-
|19|| GIWB || MG1 Phase Current W ||Grey-Black
|Green
|-
|20|| CT ||Boost converter temperature sensor||Brown-Black
|Red
|-
|21|| GIVT ||MG1 Inverter Temperature||Green-Black
|White
|-
|22|| GFIV ||MG1 Inverter Fail||White-Grey
|Grey
|-
|23|| MIWA ||MG2 Phase Current W||Grey-Green
|Red
|-
|24|| MIWB ||MG2 Phase Current W||Grey-Red
|Black
|-
|25|| MSDN ||MG2 Shutdown||Brown
|Green
|-
|26|| MIVT ||MG2 Inverter Temperature||Green
|Light Blue
|-
|27|| MFIV ||MG2 Inverter Fail||White
|Green
|-
|28|| OVH ||Overvoltage||Pink
|Brown
|-
|29|| CSDN ||Boost converter shutdown signal||Brown-White
|White
|-
|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
|}
 
== DC-DC Converter ==
[[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.
 
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.
 
'''<u>Note:</u>''' 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.
 
== Inverter Cooling ==
 
Inverter 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.
 
 
== Through Hole Control Board ==
[[File:Prius Board v1.jpg|thumb|Prius Board v1]]
 
The Toyota Prius Gen2 Board is an open source project to repurpose 2004-2009 Toyota Prius inverters for DIY EV use. It consists of a circuit board and programming that replaces the original logic board, connected to the inverter and allows independent control of it without communicating with a Prius ECU.
 
Note that there is also a [[Toyota Prius Gen3 Board]] for the 2010-2015 model years.
 
As designed by Damien Maguire, the open source hardware for the control board can be purchased as blank, unpopulated boards on his website: [https://evbmw.com/index.php/evbmw-webshop/toyota-bare-boards/prius-gen-2-inverter-bare-logic-board Prius Gen2 Logic Board on EVBMW's Webshop]
 
=== How To Use ===
The Prius Gen2 Board is suitable to control any (please add: motor types here) motors.
 
Note: There is a mistake in the printing on the v1 circuit board. The parts labelled T1, T2, and T3 - which are the small black transistors in the upper right of the board - are all drawn backwards to how they need to be inserted. These parts should be installed with the flat side of the component facing the opposite direction as the printing shows. The flat side should be to the right.
 
Schematics, Bill of Materials, and other documentation are available on [https://github.com/damienmaguire/Prius-Gen-2-Inverter Damien's Project Github]
(note: flesh out bill of materials here, or post changes to Damien to update his documentation directly?)
[[File:Prius Gen 2 inverter lower casing internals.png|thumb|300x300px|Prius gen 2 inverter lower casing internals]]
The control board utilizes the Blue Pill (link?) micro controller, and takes advantage of the OpenInverter.org software (link?) for control. It is also connected from the outside via the main (32 pin white) OEM connector - try to retrieve this connector and part of wiring loom when sourcing your inverter. Picture of connector further down in wiki.
 
The  control board design incorporates the use of the existing inverter Current Sensors - if FOC option is to be used (Gen 2 Transaxle MG2), bandwidth should be a multiple of control loop frequency which is 8.8kHz. (link to how to modify original setup?)
 
Functionality of the existing resolver is integrated as well. 
 
Assembly notes?
Blue Pill programming notes or just links to Blue Pill section?
 
Try to get all the wiring harness bits that plug into the inverter when you purchase it. Else, the 32-pin connector inside the inverter part number is: 1318747-1, and the pins to wire it are: 1123343-1
 
Terminal Block Connection list (rough, in-progress):
 
=== Wire Connections ===
[[File:Prius Control Board Wiring Diagram.jpg|alt=|thumb|700x700px|Prius Control Board - Wiring Map (click to see fullsize details)]]
'''Control Board Pin mapping:'''
 
{| class="wikitable"
! Pin # !! Designation !! Description
|-
|TB1-1
||12v-in
||Primary 12v supply from ignition on
|-
|TB1-2
|GND
||Primary ground connection to 12v negative. All grounds are common
|-
|TB1-3
|5v VCC
||5V supply from board for use with throttle pot or hall pedal
|-
|TB1-4
|Throttle In
||0-5v variable voltage input from throttle pedal or pot
|-
|TB1-5
|Regen In
||0-5v variable voltage input. Can be used as second throttle channel or control regen from a brake pressure sensor
|-
|TB1-6
|GND
|-
|TB1-7
|Brake In
||12v digital input from brake light switch.
|-
|TB1-8
|Start In
||12v digital input from "Start" position on a traditional ignition switch. Momentary action push button can be used.
|-
|TB1-9
|For In
||12v digital input commands motor to run in forward direction
|-
|TB1-10
|Rev In
||12v digital input commands motor to run in reverse direction
|-
|TB3-1
| +12v VCC
||12v output to inverter IGCT terminal (Not on the 32-pin connector, the red wire on the 2-pin connector next to it).
|-
|TB3-2
|GND
|Common ground, but used to connect to inverter GND terminal (Not on the 32-pin connector, the black wire on 2-pin connector next to it).
|-
|TB3-3
|Phase U ||
Phase U output. Connect to Inverter MUU terminal for MG2 inverter drive or GUU for MG1 inverter drive
|-
|TB3-4
|Phase Y
||Phase V output. Connect to Inverter MVU terminal for MG2 inverter drive or GVU for MG1 inverter drive
|-
|TB3-5
|Phase W
||Phase W output. Connect to Inverter MWU terminal for MG2 inverter drive or GWU for MG1 inverter drive
|-
|TB3-6
|Current U
||Phase currents from inverter. Requires external divider circuit. Not required to run motor or inverter.
|-
|TB3-7
|Current Y
||Phase currents from inverter. Requires external divider circuit. Not required to run motor or inverter.
|-
|TB3-8
|MG2 Enable
||Connect to Inverter MSDN to run MG2 inverter or GSDN to run MG1 inverter
|-
|TB3-9
|MG2 Fault
||Connect to MFIV for MG2 or GFIV for MG1
|-
|TB3-10
|DC Bus
||Connect to inverter VH to measure DC link voltage
|-
|TB2-1
| +5V VCC
||5v output to encoder for induction motor
|-
|TB2-2
|ENCA In
||Encoder input A
|-
|TB2-3
|ENCB In
||Encoder input B
|-
|TB2-4
|GND
|Encoder ground
|-
|TB2-5
|HS Temp
||Heatsink temp sensor input
|-
|TB2-6
|MOT Temp
||Motor temp sensor input
|-
|TB4-1
|GND
|Common ground
|-
|TB4-2
|Main Con
||Main HV contactor control low side switch
|-
|TB4-3
|Precharge
||HV precharge contactor control low side switch
|-
|TB4-4
| +12 V VCC
||Spare 12v output
|-
|TB4-5
|CAN L
||Can bus low signal
|-
|TB4-6
|CAN H
||Can bus high signal
|}
 
== New SMT control board with enclosure and designated pinouts ==
Please add pictures and description.
 
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 Gen2 Inverter.png|thumb|VCU to Prius Gen2 wiring]]
Pin#09 - START_IN (12V)
 
Pin#10 - BRAKE_IN (12V)
[[File:Adapter board pin outs.png|thumb|Adapter Board Pin out locations]]
Pin#11 - FORWARD_IN (12V) (1, 2 or 3 way switch)
 
Pin#12 - REVERSE_IN (12V)  (1, 2 or 3 way switch)
 
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 for charge mode.
 
Connect the 2-pole white power connector ("I9") inside inverter to 12V and Ground to power up inverter electronics.
 
'''<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 !
 
== 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
 
'''''<u>Do NOT program a deadtime value for the Gen2 inverter.</u>''''' It only uses 1 PWM per phase and the inverter itself generates a low-side and high-side signal WITH deadtime.

Latest revision as of 10:21, 14 June 2023

This page is now deprecated in favor of the following new pages:

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