• Kevin McAndrew

Prius

32 Pin Connector Detail

Many of the figures are taken from P112 HYBRID VEHICLE CONTROL manual: http://static.hybrids.ru/files/OfficialToyotaInfo/RepairInformation/RepairManual/HV%20-%20P112%20Hybrid%20Vehicle%20Control.pdf

32 pin connector 🔌

This section will include a pin-by-pin investigation into the details of each of the 32 pin connector pins.


Unused…


  1. GIVA : MG1 phase current V
  2. GIVB : MG1 phase current V

Current sensor pins. What voltage are they? How is current sensed?

current-sensors
  1. GUU : MG1 PWM U
  2. GVU : MG1 PWM V
  3. GWU : MG1 PWM W

Can these control the IGBTs when the shutdown pin (pin 14) is turned off? What voltage PWM? What frequency can be used?


  1. MIVA : MG2 phase current V
  2. MIVB : MG2 phase current V

Refer to pins 2 and 3


  1. MUU : MG2 PWM U
  2. MVU : MG2 PWM V
  3. MWU : MG2 PWM W

Refer to pins 4, 5 and 6


  1. VH : Inverter capacitor voltage
vh-curve
  1. CPWM : Boost converter switch signal
cpwm-signal
  1. GSDN : MG1 shutdown

Maybe swapped with pin 20 (CT)???


  1. VL : Boost converter input voltage
vl-curve
  1. GINV : Inverter ground

Unused…


  1. GIWA : MG1 phase current W
  2. GIWB : MG1 phase current W

Refer to pins 2 and 3


  1. CT : Boost converter temperature sensor

Maybe swapped with pin 14 (GSDN)??? - It seems so

ct-curve
  1. GIVT : MG1 inverter temperature
ct-curve
  1. GFIV : MG1 inverter fail

Where does the error come from?


  1. MIWA : MG2 phase current W
  2. MIWB : MG2 phase current W

Refer to pins 2 and 3


  1. MSDN : MG2 shutdown

Refer to pin 14


  1. MVIT : MG2 inverter temperature

Refer to pin 20 and 21


  1. MFIV : MG2 inverter fail

Refer to pin 22


  1. OVH : Overvoltage

  1. CSDN : Boost converter shutdown signal

  1. FCV : Boost converter fail signal

  1. OVL : Boost converter over voltage signal

  1. GCNV : Boost converter ground

Boost Converter Module

https://nicjam.es/projects/how-to-turn-on-the-gen2-prius-boost-converter-module/

PM400JA120

Pinout:

  1. CT? (Green/Red) - Seems to be connected to GSDN pin on connector A
  2. VL [scaled] (Purple/White)
  3. OVH (Pink) - also connected to the inverter
  4. CPWM (Blue)
  5. GINV (Black)
  6. IGCT (Red)
  7. Battery Connection (Orange with spade)
  8. OVL (Blue/Pink)
  9. FCV (Red/White)
  10. GCNV (Black)
  11. CSDN (Brown)

Converter tests

Conditions:

Tests:

Results:


NO PWM

Result:


PWM connected to ground

Result (diode test mode):


PWM connected to 12V

Result (diode test mode):


Shutdown pin ON

Result (diode test mode):


No power

Result (diode test mode):


PWM current

Inverter / Converter tests

Test the rectified waveform using the scaled VH pin

rectified mains

Main Board IPM

http://techno-fandom.org/~hobbit/cars/ginv/