Up to 08/2009

HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM: P0A94-557: DC / DC Converter Performance
P0A94-557 - DC / DC Converter Performance

DESCRIPTION

The boost converter boosts the 288 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 MG1, MG2 and MGR. When a motor generator operates as a generator, the alternating current that it creates is converted into direct current by the inverter. Then the boost converter drops this voltage to direct-current of approximately 288 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 MG ECU controls the operation of the boost converter to boost the voltage to the target voltage.

If a malfunction occurs in the boost converter, the MG ECU detects it and transmits this information to the power management control ECU (HV CPU).





MONITOR DESCRIPTION

If the boost converter detects a circuit malfunction, it will transmit a boost converter fail signal to the MG ECU. The MG ECU will send information about the malfunction to the power management control ECU (HV CPU). Upon receiving this information, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

MONITOR STRATEGY





TYPICAL ENABLING CONDITIONS





TYPICAL MALFUNCTION THRESHOLDS





COMPONENT OPERATING RANGE





CONFIRMATION DRIVING PATTERN





- Connect the Techstream to the DLC3.

- Turn the power switch on (IG) and turn the Techstream on.

- Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).

- Turn the power switch off.

- Turn the power switch on (IG) and check that there are no abnormalities (abnormal sounds, coolant leaks, DTC output, etc).

- Turn the power switch on (READY) and turn the Techstream on. [A]

- With the shift lever in P, wait for several seconds.

- Enter the following menus: Powertrain / Hybrid Control / Trouble Codes. [B]

- Check that permanent DTCs are cleared.

- If the permanent DTCs are not cleared, perform a universal trip, and then check for permanent DTCs again.

HINT
- If a permanent DTC is output, the system is malfunctioning.
- If no permanent DTC is output, the system is normal.
WIRING DIAGRAM













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.
NOTICE:
After troubleshooting and repairing all output DTCs, be sure to replace the inverter with converter assembly.

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) Enter the following menus: 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 procedure.
- P0A94-557 may be set due to a malfunction which also causes DTCs in the preceding table to be set. In this case, first troubleshoot the output DTCs in the preceding table. Then, perform a test to attempt to reproduce the problems, and check that no DTCs are output. After troubleshooting and repairing all output DTCs, be sure to replace the inverter with converter assembly.
(e) Turn the power switch off.

B -- GO TO DTC CHART Hybrid Control System
A -- 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 QUANTITY OF HV COOLANT P0A01

C -- INSPECT FOR COOLANT LEAK AND ADD COOLANT

B -- ADD HV COOLANT
A -- Continue to next step.

4. CHECK COOLANT HOSE P0A01

NG -- CORRECT THE PROBLEM
OK -- Continue to next step.

5. PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE ELECTRIC COOLING FAN) P0A01

NG -- CHECK COOLING FAN SYSTEM Cooling Fan Circuit
OK -- Continue to next step.

6. CHECK HV COOLANT (CHECK FOR CONDITIONS THAT MAY HAVE CAUSED FREEZING) P0A08

B -- REPLACE HV COOLANT
A -- Continue to next step.

7. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER) P0A1A

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

8. CHECK GENERATOR RESOLVER P0A1A

NG -- CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR)
OK -- Continue to next step.

9. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER) P0A1A

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

10. CHECK MOTOR RESOLVER P0A1A

NG -- CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR)
OK -- Continue to next step.

11. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - REAR MOTOR RESOLVER) P0A1A

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

12. CHECK REAR MOTOR RESOLVER P0A1A

NG -- CHECK CONNECTOR CONNECTION CONDITION (REAR MOTOR RESOLVER CONNECTOR)
OK -- Continue to next step.

13. CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION) P0A78

C -- CONNECT SECURELY

B -- REPLACE MALFUNCTIONING PARTS
A -- Continue to next step.

14. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION) P0A78

C -- CONNECT SECURELY

B -- REPLACE MALFUNCTIONING PARTS
A -- Continue to next step.

15. CHECK INVERTER WITH CONVERTER ASSEMBLY (REAR MOTOR CABLE CONNECTION CONDITION) P0A78

C -- CONNECT SECURELY

B -- REPLACE MALFUNCTIONING PARTS
A -- Continue to next step.

16. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1) P0A78

NG -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Components
OK -- Continue to next step.

17. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG2) P0A78

NG -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Components
OK -- Continue to next step.

18. CHECK REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY (MGR) P0A78

NG -- CHECK REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY (REAR MOTOR CABLE CONNECTION CONDITION)
OK -- Continue to next step.

19. CHECK FUSE (PCU) P0A78

NG -- CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE)
OK -- Continue to next step.

20. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT) P0A78

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

21. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - INVERTER WITH CONVERTER) P0A78

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

22. CHECK POWER MANAGEMENT CONTROL ECU P0A78

NG -- REPLACE POWER MANAGEMENT CONTROL ECU Components
OK -- Continue to next step.

23. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) P0A1A

NG -- CONNECT SECURELY
OK -- Continue to next step.

24. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) P0A1A

NG -- CONNECT SECURELY
OK -- Continue to next step.

25. CHECK CONNECTOR CONNECTION CONDITION (REAR MOTOR RESOLVER CONNECTOR) P0A1A

NG -- CONNECT SECURELY

OK -- REPLACE INVERTER WITH CONVERTER ASSEMBLY Components

26. REPLACE HV COOLANT P0A01

NEXT -- Continue to next step.

27. CHECK WATER PUMP WITH MOTOR ASSEMBLY P0A01

NG -- REPLACE WATER PUMP WITH MOTOR ASSEMBLY Components

OK -- COMPLETED

28. CHECK CONNECTOR CONNECTION CONDITION (GENERATOR RESOLVER CONNECTOR) P0A1A

NG -- CONNECT SECURELY
OK -- Continue to next step.

29. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - GENERATOR RESOLVER) P0A1A

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Components

30. CHECK CONNECTOR CONNECTION CONDITION (MOTOR RESOLVER CONNECTOR) P0A1A

NG -- CONNECT SECURELY
OK -- Continue to next step.

31. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - MOTOR RESOLVER) P0A1A

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY Components

32. CHECK CONNECTOR CONNECTION CONDITION (REAR MOTOR RESOLVER CONNECTOR) P0A1A

NG -- CONNECT SECURELY
OK -- Continue to next step.

33. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - REAR MOTOR RESOLVER) P0A1A

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY Components

34. CHECK REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY (REAR MOTOR CABLE CONNECTION CONDITION) P0A78

C -- CONNECT SECURELY

B -- REPLACE MALFUNCTIONING PARTS
A -- Continue to next step.

35. CHECK NO.3 WIRE FRAME (REAR MOTOR CABLE) P0A78

NG -- REPLACE NO.3 WIRE FRAME Components
OK -- Continue to next step.

36. CHECK EXTENSION WIRE ASSEMBLY P0A78

NG -- REPLACE EXTENSION WIRE ASSEMBLY Components

OK -- REPLACE REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY Components

37. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE) P0A78

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

38. REPLACE INVERTER WITH CONVERTER ASSEMBLY

(a) Replace the inverter with converter assembly Components.

NEXT -- REPLACE FUSE (PCU)

39. REPAIR OR REPLACE HARNESS OR CONNECTOR

NEXT -- REPLACE FUSE (PCU)