P0A94-557
P112 HYBRID VEHICLE CONTROL: HYBRID CONTROL SYSTEM: P0A94-557: DC / DC Converter Performance
DTC P0A94-557 - 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.
If the boost converter has a circuit malfunction, internal short, or overheats, the boost converter transmits that information to the FCV terminal of the HV control ECU via the boost converter fail signal line.
MONITOR DESCRIPTION
If the boost converter detects a circuit malfunction, it transmits a boost converter fail signal to the HV control ECU. Upon receiving this signal, 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. READ OUTPUT DTC (HV ECU)
(a) Connect the Techstream to the DLC3.
(b) Turn the power switch ON (IG).
(c) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
(d) Check if DTCs are output.
Result:
DTC listed in the table below is output
YES -- GO TO THE TEST INDICATED IN THE TABLE ABOVE
NO -- Continue to next step.
2. 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.
(e) Reinstall the inverter cover Installation.
(f) Reinstall the service plug grip Installation.
NG -- CONNECT SECURELY
OK -- Continue to next step.
3. READ OUTPUT DTC (HV ECU)
(a) Connect the Techstream to the DLC3.
(b) 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.
(c) Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.
(d) Check if DTCs are output.
Result:
DTCs P0A78 (INF 282, 286) and P0A7A (INF 324) (inverter circuit malfunction) are output
NO -- REPLACE INVERTER WITH CONVERTER ASSEMBLY
YES -- Continue to next step.
4. INSPECT INVERTER WITH CONVERTER ASSEMBLY (IGCT VOLTAGE)
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) 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 inverter connector.
Standard voltage:
(f) Turn the power switch OFF.
(g) Reinstall the inverter cover Installation.
(h) Reinstall the service plug grip Installation.
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY