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Specs / supplier for orange HV wire?

Discussion in 'Gen 2 Prius Technical Discussion' started by ChapmanF, Mar 30, 2008.

  1. ChapmanF

    ChapmanF Senior Member

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    I've been looking at a lot of pics of various PriUPS-type conversions
    and it has occurred to me that in adding a tap from the SMR to
    an Anderson connector somewhere, I really ought to try to get
    wire of a similar insulation type (and orangeness) to the OE wire.

    I haven't looked closely enough at the wire (gloves haven't arrived
    yet) to see if there are any wire-type markings printed on the
    insulation (or even if the insulation itself is really orange, or
    just the plastic split-loom they wrap around it).

    Has anybody already looked for that and read wire type,
    voltage, and temperature ratings off the OE wire? Does
    anybody know of a source for the stuff?

    I suppose I could always buy an OE power cable and cut it up,
    and have some left over. I just haven't priced that option yet.

    Thanks,
    -Chap
     
    #1 ChapmanF, Mar 30, 2008
  2. krousdb

    krousdb NX-74205

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    Here is what was used to add battery capacity to my OEM pack. I had six 3ah packs wired in parallel fed thru two 120A circuit breakers and a solenoid which activated when the car was started. The cable insulation is black but is covered in the orange harness stuff that i cant remember the name of. Anyway, if any of this is of use to you let me know. I would be willing to part with it.

    [​IMG]

    Dan
     
    #2 krousdb, Mar 30, 2008
  3. hobbit

    hobbit Senior Member

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    The cables themselves are special coaxial ones with grounded
    shields. (Picture) For wiring contained inside the car, you
    probably don't need wiring like that as the stock cables shown
    are the ones that pass outside the passenger compartment to
    the front and are more likely to get damaged/punctured if
    something bad happens. That kicks the ground-fault detection
    circuitry to disable the battery relays.
    .
    It would be nice to know a handy source for orange split-loom
    plastic sleeving, though.
    .
    _H*
     
    #3 hobbit, Mar 31, 2008
  4. David Beale

    David Beale Senior Member

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    You can get split loom sleeving in just about any colour you like. Try the car parts specialists who sell to the import crowd. I've also seen it in my local electronics parts supplier (MRO).
     
    #4 David Beale, Mar 31, 2008
  5. ChapmanF

    ChapmanF Senior Member

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    Thanks for the pic. (Hm, the angle is a little disorienting ... izzat a Prius inverter on its side, from the back, with the power cable connectors exposed and maybe MG2 u and v ruthlessly chopped off at the top? Or am I completely lost?)

    I wonder whether the shield is only for fault detection. ISTR reading somewhere that someone had measured a largish (like 100V amplitude) AC common mode signal on the power cables during inverter operation; I wonder if they're also trying not to be a source of interference.

    I still don't see any sign of identifying print or stamping on the insulation. I think my local electronics shoppe does have split loom in various colors, but I suspect if I ask them for orange power coax with 600V insulation and >50A capacity they're going to look at me funny. I guess if I found a salvage yard with just about any model of hybrid vehicle I'd be able to get suitable stuff....

    -Chap
     
    #5 ChapmanF, Apr 1, 2008
  6. engrx2

    engrx2 Junior Member

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    I need to remove the inverter from my car to work on the brake actuator. I am wondering if you can tell me how to disconnect the three orange wire from the rear and three orange wires on the right side of the inverter. Thanks
     
    #6 engrx2, Apr 20, 2008
  7. hobbit

    hobbit Senior Member

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    http://techno-fandom.org/~hobbit/cars/maint50k/ describes
    lifting the inverter a bit. To completely remove it you'll
    have to drain the coolant and disconnect hoses; I was trying
    to avoid that.
    .
    What's up with your brake system?
    .
    _H*
     
    #7 hobbit, Apr 20, 2008
  8. ChapmanF

    ChapmanF Senior Member

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    Champlain Cable makes several flavors of the stuff.
    Champlain Cable - Automotive

    Now to see if any of my local auto electrical outfits are able to get it.

    A couple of the flavors are only slightly over 5 mm outside finished diameter for an 80 amp rating (more than adequate for any PriUPS).

    They do seem to tout the shielding as an EMI/RFI control feature, and not merely as a sentinel for insulation failure.

    -Chap
     
    #8 ChapmanF, Apr 24, 2008
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