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P0A94-127








P311 HYBRID VEHICLE CONTROL: HYBRID CONTROL SYSTEM: P0A94-127: DC / DC Converter Performance

DTC P0A94-127 - DC / DC Converter Performance

DESCRIPTION

The boost converter boosts the 244.8 V DC from the HV battery to a maximum of approximately 650 V DC. The inverter converts the voltage that has been boosted by the boost converter into alternating current, which is used for driving MG2 and MG1. When MG1 and MG2 operate as a generator, the alternating-current voltage from MG1 and MG2 is converted into direct-current voltage by the inverter. Then the boost converter drops this voltage to a direct-current voltage rating of 244.8 V in order to charge the HV battery.





The MG ECU uses a voltage sensor (VL) that is built into the boost converter to detect the high voltage before it is boosted. It also uses a voltage sensor (VH) that is built into the inverter to detect the high voltage after it is boosted. Based on the voltage before and after it is boosted, the hybrid vehicle control ECU controls the operation of the boost converter to boost the voltage to the target voltage.

If the boost converter detects a circuit malfunction or overvoltage, it transmits this information to the OVL terminal of the MG ECU via the boost converter overvoltage signal line.






INSPECTION PROCEDURE
CAUTION:
- Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
- After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals. After waiting for 10 minutes, check the voltage at the terminals in the inspection point in the inverter with converter assembly. The voltage should be 0 V before beginning work.
HINT: Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

PROCEDURE

1. CHECK DTC OUTPUT (HV)
(a) Connect the Techstream to the DLC3.
(b) Turn the power switch on (IG).
(c) Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
(d) Check if DTCs are output.
Result:





HINT:
- *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic flowchart.
- Turning the power switch on (IG) with the service plug grip and inverter cover removed causes interlock switch system DTC P0A0D-350 to be output.
- P0A94-127 may be output due to a malfunction which causes the DTCs in the table above to be output. In this case, first troubleshoot the output DTCs in the table above. Then, perform a reproduction test to check that no DTCs are output.

YES -- GO TO DTC CHART
NO -- Continue to next step.
2. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR) P0343
NG -- CONNECT SECURELY
OK -- Continue to next step.
3. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER) P0A1A
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
4. CHECK GENERATOR RESOLVER P0A1A
NG -- CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)
OK -- Continue to next step.
5. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER) P0A1B
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
6. CHECK MOTOR RESOLVER P0A1B
NG -- CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)
OK -- Continue to next step.
7. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION) P0A1B
NG -- TIGHTEN TO SPECIFIED TORQUE
OK -- Continue to next step.
8. CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION) P0A1B
NG -- TIGHTEN TO SPECIFIED TORQUE
OK -- Continue to next step.
9. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1) P0A1B
NG -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY
OK -- Continue to next step.
10. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2) P0A1B
NG -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY
OK -- Continue to next step.
11. CHECK INVERTER WITH CONVERTER ASSEMBLY (HIGH VOLTAGE CONNECTOR CONNECTION CONDITION) P0A78
NG -- CONNECT SECURELY
OK -- Continue to next step.
12. CHECK SERVICE PLUG GRIP P0A78
NG -- REPLACE SERVICE PLUG GRIP
OK -- Continue to next step.
13. CHECK SERVICE PLUG GRIP P0A78
NG -- REPLACE SERVICE PLUG GRIP
OK -- Continue to next step.
14. CHECK CONDITION OF FRAME WIRE CONNECTION(S) (HV RELAY ASSEMBLY SIDE) P3004
NG -- TIGHTEN TO SPECIFIED TORQUE
OK -- Continue to next step.
15. CHECK FRAME WIRE P0A78
NG -- REPLACE FRAME WIRE
OK -- Continue to next step.
16. INSPECT HV RELAY ASSEMBLY (SMRB) P0A78
NG -- REPLACE HV RELAY ASSEMBLY
OK -- Continue to next step.
17. INSPECT HV RELAY ASSEMBLY (SMRG) P0A78
NG -- REPLACE HV RELAY ASSEMBLY
OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY
18. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) P0A1B
NG -- CONNECT SECURELY
OK -- Continue to next step.
19. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER) P0A1B
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY
20. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) P0A1A
NG -- CONNECT SECURELY
OK -- Continue to next step.
21. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER) P0A1A
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY
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