P0A94-560

P112 HYBRID VEHICLE CONTROL: HYBRID CONTROL SYSTEM: P0A94-558: DC / DC Converter Performance

DTC P0A94-558 - DC / DC Converter Performance

DTC P0A94-559 - DC / DC Converter Performance

DTC P0A94-560 - DC / DC Converter Performance

DESCRIPTION

The boost converter contains a booster IPM (Intelligent Power Module), which includes an IGBT (Insulated Gate Bipolar Transistor) and a reactor. The HV control ECU actuates the IGBT, which controls the current in the reactor.
The boost converter boosts the high-voltage direct current rated at 201.6 V to an approximate direct current voltage of 500 V. The inverter converts the voltage that has been boosted by the boost converter into alternating current, which is used for driving the MG1/MG2. When the MG1/MG2 operates as a generator, the alternating current of approximately 500 V from the MG1/MG2 is converted into direct current by the inverter.
Then, the boost converter drops this voltage to a direct current voltage rated at 201.6 V in order to charge the HV battery.





The HV control ECU uses a voltage sensor that is built into the boost converter to detect the high voltage (VL) before it is boosted. Also, it uses a voltage sensor that is built into the inverter to detect the high voltage (VH) after it has been boosted.
Based on the voltage before and after it has been boosted, the HV control ECU boosts it to a target voltage by controlling the operation of the boost converter.

Upon receiving a boost converter gate shutdown signal from the HV control ECU, the boost converter forcefully stops the operation of the boost converter by turning OFF the power transistors that are actuating the boost converter.
The HV control ECU monitors the boost converter gate shutdown signal line and detects a malfunction.






MONITOR DESCRIPTION

The HV control ECU monitors the boost converter gate shutdown (CSDN) signal line. If the HV control ECU detects an open or short malfunction of the CSDN signal circuit, the HV control ECU illuminates the MIL and sets a DTC.

MONITOR STRATEGY





TYPICAL ENABLING CONDITIONS





TYPICAL MALFUNCTION THRESHOLDS





COMPONENT OPERATING RANGE





WIRING DIAGRAM





INSPECTION PROCEDURE
CAUTION:
- Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system.
- After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals.
HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter.

PROCEDURE

1. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER)




(a) Disconnect the H16 HV control ECU connector.
(b) Measure the voltage between the terminal of the HV control ECU connector and body ground.
Standard voltage:






NG -- CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER)
OK -- Continue to next step.

2. CHECK INVERTER AND HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER)




CAUTION: Wear insulated gloves before performing the following operation.
(a) Turn the power switch OFF.
(b) Remove the service plug grip Removal.
NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state.
(c) Remove the inverter cover Removal.
(d) Measure the resistance between the wire harness side connectors.
Standard resistance:





NOTE: When measuring the resistance, wait until the value is stable before reading the tester.

OK -- REPLACE HYBRID VEHICLE CONTROL ECU
NG -- Continue to next step.

3. CHECK INVERTER AND HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER)




(a) Disconnect the I10 inverter connector.
(b) Measure the resistance between the wire harness side connectors and body ground.
Standard resistance (Check for open):






Standard resistance (Check for short):





(c) Reinstall the inverter cover Installation.
(d) Reinstall the service plug grip Installation.
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY
4. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER)




CAUTION: Wear insulated gloves before performing the following operation.
(a) Turn the power switch OFF.
(b) Remove the service plug grip Removal.
NOTE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state.
(c) Remove the inverter cover Removal.
(d) Measure the resistance between the wire harness side connectors.
HINT: DTCs for the interlock switch system are output when the power switch is turned ON (READY) while the service plug grip and inverter cover are removed.

Standard voltage:






NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY