P3226-562
P112 HYBRID VEHICLE CONTROL: HYBRID CONTROL SYSTEM: P3226-562: DC/DC Boost Converter Temperature Sensor
DTC P3226-562 - DC/DC Boost Converter Temperature Sensor
DTC P3226-563 - DC/DC Boost Converter Temperature Sensor
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.
The HV control ECU uses a temperature sensor, which is built into the boost converter, to detect the temperature of the boost converter.
The boost converter temperature sensor outputs a voltage, which varies between 0 and 5 V in accordance with the changes in the temperature. The higher the boost converter temperature, the lower the output voltage. Conversely, the lower the temperature, the higher the output voltage.
The HV control ECU limits the load based on the signals transmitted by the boost converter temperature sensor, in order to prevent the boost converter from overheating. Furthermore, the HV control ECU detects a malfunction in the wiring of the boost converter temperature sensor, as well as in the sensor itself.
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 QUANTITY OF HV COOLANT
(a) Check that there is a sufficient amount of coolant for the inverter.
OK:
There is a sufficient amount of coolant for the inverter
NG -- ADD HV COOLANT
OK -- Continue to next step.
2. CHECK COOLANT HOSE
(a) Check that the hoses of the cooling system are not bent or clogged (refer to the cooling system [ P0A93]).
OK:
The hoses of the cooling system are not bent or clogged
NG -- CORRECT TO NORMAL CONDITION
OK -- Continue to next step.
3. CHECK CONNECTOR CONNECTION CONDITION (WATER PUMP CONNECTOR AND SHORT CONNECTOR)
(a) Check the connection condition of the water pump connector.
OK:
Connector has been connected securely and there is no poor connection.
(b) Check the connection condition of the short connector.
OK:
Connector has been connected securely and there is no poor connection.
NG -- CONNECT SECURELY
OK -- Continue to next step.
4. CHECK WATER PUMP W/ MOTOR AND BRACKET ASSEMBLY
(a) Turn the power switch ON (IG).
(b) Check the operation of the water pump.
OK:
Coolant is sloshing in the reservoir tank
NG -- CHECK WATER PUMP W/ MOTOR AND BRACKET ASSEMBLY
OK -- Continue to next step.
5. CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONTACT)
(a) Check the connection condition of the cooling fan motor connectors.
OK:
Connectors have been connected securely and there is no poor connection.
NG -- CONNECT SECURELY
OK -- Continue to next step.
6. INSPECT COOLING FAN MOTOR
(a) Inspect the cooling fan motor Testing and Inspection.
NG -- REPLACE COOLING FAN MOTOR AND ADD ENGINE COOLANT
OK -- Continue to next step.
7. INSPECT NO. 2 COOLING FAN MOTOR
(a) Inspect the No. 2 cooling fan motor Testing and Inspection.
NG -- REPLACE NO. 2 COOLING FAN MOTOR AND ADD ENGINE COOLANT
OK -- Continue to next step.
8. CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT)
(a) Check the connection condition of all the connectors at the HV control ECU.
OK:
Connectors have been connected securely and there is no poor connection.
NG -- CONNECT SECURELY
OK -- Continue to next step.
9. CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT)
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) Check the connection condition of the I9 and I10 inverter connectors.
OK:
Connectors have been connected securely and there is no poor connection.
NG -- CONNECT SECURELY
OK -- Continue to next step.
10. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER)
CAUTION: Wear insulated gloves before performing the following operation.
(a) Check that the service plug grip and inverter cover have been removed.
(b) Disconnect the H16 HV control ECU connector.
(c) Disconnect the I9 and I10 inverter connectors.
(d) Turn the power switch ON (IG).
HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed.
(e) Measure the voltage between the terminals of the HV control ECU connector and body ground.
Standard voltage:
(f) Turn the power switch OFF.
(g) Measure the resistance between the wire harness side connectors.
Standard resistance (Check for open):
Standard (Check for short)
(h) Reconnect the inverter connectors.
(i) Reconnect the HV control ECU connector.
(j) Reinstall the inverter cover Installation.
(k) Reinstall the service plug grip Installation.
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY
11. CHECK WATER PUMP W/ MOTOR AND BRACKET ASSEMBLY
(a) Remove the water pump w/ motor and bracket assembly.
(b) Connect the battery positive terminal to terminal 2 and the battery negative terminal to terminal 1.
(c) Check that the water pump w/ motor and bracket assembly operates properly.
NOTICE:
- Do not connect the positive and negative poles of the battery to the wrong terminals.
- Complete the check within 10 seconds of connection.
OK:
Water pump w/ motor and bracket assembly operates properly.
NG -- REPLACE WATER PUMP W/ MOTOR AND BRACKET ASSEMBLY
OK -- REPAIR OR REPLACE HARNESS OR CONNECTOR (WATER PUMP W/MOTOR AND BRACKET ASSEMBLY POWER SOURCE CIRCUIT)