Hybrid Control System (Diagnostic Codes (P0A7A-325 - P0AE6-225)): Overview Lexus CT I

DESCRIPTION

For a description of the inverter. Refer to DESCRIPTION .

If the generator inverter overheats, has a circuit malfunction or has an internal short, the inverter transmits this information to the MG ECU via the generator inverter fail signal line.

If an abnormal amount of current flows through the generator inverter, the MG ECU detects it and sends a signal to inform the power management control ECU (HV CPU) of the malfunction.

MONITOR DESCRIPTION

P0A7A (INF 325)

If excessive amperage flows through the generator inverter due to an internal short, the generator inverter will transmit an inverter fail signal to the MG ECU. Upon receiving this information, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

P0A7A (INF 810)

If the MG ECU detects that the generator inverter current exceeds the threshold level for a period of time, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

For a description of the inverter. Refer to DESCRIPTION .

If the MG1 torque execution value does not correspond to the torque command value from the MG ECU to MG1, the power management control ECU (HV CPU) will store this DTC.

If the difference between the requested MG1 torque and the actual MG1 torque exceeds a predetermined value, the MG ECU determines that there is a malfunction in the execution or monitoring of MG1 torque. 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.

For a description of the inverter. Refer to DESCRIPTION .

If the generator inverter overheats, has a circuit malfunction or has an internal short, the inverter transmits this information to the MG ECU via the generator inverter fail signal line.

If an abnormal amount of current flows through the generator inverter, the MG ECU detects it and sends a signal to inform the power management control ECU (HV CPU) of the malfunction.

P0A7A (INF 517)

If excessive amperage flows through the generator inverter due to an internal short, the generator inverter will transmit an inverter fail signal to the MG ECU. Upon receiving this signal, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

P0A7A (INF 809)

If the MG ECU detects that the generator inverter current exceeds the threshold level for a period of time, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

For a description of the inverter. Refer to DESCRIPTION .

If the generator inverter overheats, has a circuit malfunction or has an internal short, the inverter transmits this information to the MG ECU via the generator inverter fail signal line.

If an abnormal amount of current flows through the generator inverter, the MG ECU detects it and sends a signal to inform the power management control ECU (HV CPU) of the malfunction.

P0A7A (INF 518)

If excessive amperage flows through the generator inverter due to an internal short, the generator inverter will transmit an inverter fail signal to the MG ECU. Upon receiving this signal, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

P0A7A (INF 811)

If the MG ECU detects that the generator inverter current exceeds the threshold level for a period of time, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

When three-phase alternating current flows through the three-phase windings of the stator coil, a rotating magnetic field is generated in motor. The system controls the rotation of the magnetic field in accordance with the rotating position and speed of the rotor. As a result, the permanent magnets provided in the rotor are pulled in the direction of rotation, generating torque. The generated torque is almost proportional to the amount of current. The system controls motor speed by regulating the frequency of the alternating current. Furthermore, the system properly controls the rotating magnetic field and the angle of the rotor magnets in order to generate high torque in an efficient manner, even at high speeds.

Scheme 493

The MG ECU monitors MG2. If the MG ECU detects a reduction in the magnetic force of MG2 or an inphase short, it interprets this as an MG2 failure. The power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

For a description of MG2. Refer to DESCRIPTION .

The MG ECU monitors MG2. If the MG ECU detects a malfunction of MG2, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

For a description of MG1. Refer to DESCRIPTION .

The MG ECU monitors MG1. If the MG ECU detects a reduction in the magnetic force of MG1 or an inphase short, it interprets this as an MG1 failure. The power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

For a description of MG1. Refer to DESCRIPTION .

The MG ECU monitors MG1. If the MG ECU detects a malfunction of MG1, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

The inverter converts the high-voltage direct current of the HV battery into the alternating current for MG1 and MG2. The inverter generates heat during the conversion process. Therefore, the inverter is cooled by a special cooling system consisting of the inverter water pump assembly, the cooling fan, and a radiator. This cooling system is independent of the engine cooling system. The power management control ECU (HV CPU) monitors the electric water pump, cooling fan, and cooling system, and detects the following malfunctions.

Scheme 494

If the power management control ECU (HV CPU) detects a malfunction of the inverter water pump assembly, fan or radiator, the ECU will illuminate the MIL and set a DTC.

For a description of the boost converter. Refer to DESCRIPTION .

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).

If the boost converter detects over-voltage, it will transmit an over-voltage signal to the MG ECU. Upon receiving this signal, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

For a description of the boost converter. Refer to DESCRIPTION .

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).

If excessive amperage flows through the boost converter due to an internal short, the boost converter will transmit a boost converter fail signal to the MG ECU. Upon receiving this signal, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

The boost converter boosts the 201.6 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 and MG2. 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 201.6 V in order to charge the HV battery.

Scheme 495

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 the difference between the requested boost converter voltage and the actual boost converter voltage exceeds a predetermined value, the MG ECU determines that there is a malfunction of the execution or monitoring in the boost converter voltage. 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.

For a description of the boost converter. Refer to DESCRIPTION .

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).

If the boost converter (inverter with converter assembly) detects overvoltage, it will transmit an overvoltage signal to the MG ECU. Upon receiving this information, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

For a description of the boost converter. Refer to DESCRIPTION .

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).

If the boost converter (inverter with converter assembly) detects overvoltage, it will transmit an overvoltage signal to the MG ECU. Upon receiving this signal, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

For a description of the boost converter. Refer to DESCRIPTION .

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).

If the boost converter detects overvoltage, it will transmit an overvoltage signal to the MG ECU. Upon receiving this information, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

For a description of the boost converter. Refer to DESCRIPTION .

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).

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

For a description of the boost converter. Refer to DESCRIPTION .

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).

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

For a description of the boost converter. Refer to DESCRIPTION .

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).

If excessive amperage flows through the boost converter due to an internal short, the boost converter will transmit a boost converter fail signal to the MG ECU. Upon receiving this information, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

For a description of the boost converter. Refer to DESCRIPTION .

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).

If excessive amperage flows through the boost converter due to an internal short, the boost converter will transmit a boost converter fail signal to the MG ECU. Upon receiving this information, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

For a description of the boost converter. Refer to DESCRIPTION .

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).

If excessive amperage flows through the boost converter due to an internal short, the boost converter will transmit a boost converter fail signal to the MG ECU. Upon receiving this information, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

For a description of the boost converter. Refer to DESCRIPTION .

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).

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

Refer to the description for DTC P0A94-589. Refer to DESCRIPTION .

The power management control ECU (HV CPU) monitors the boost converter voltage sensor signal. If the power management control ECU (HV CPU) detects an abnormality in the sensor signal, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

For a description of the boost converter. Refer to DESCRIPTION .

The MG ECU uses a voltage sensor (VL) that is built into the boost converter to detect the high voltage before it is boosted. The ECU also uses the battery smart unit to detect HV battery voltage (VB).

HINT

Using the Techstream, check the Data List of HV battery voltage and current. If these values are not within the below range, there is a battery smart unit malfunction.

Scheme 496

The power management control ECU (HV CPU) monitors signals of HV battery voltage (VB) and boost converter voltage (VL) sensors. When a large difference occurs between the voltages from the VB and VL sensors, the power management control ECU (HV CPU) interprets this as a failure of either of the sensors. The power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

The MG ECU uses a voltage sensor that is built into the boost converter to detect pre-boost high voltage (VL) to allow boost control. The MG ECU monitors the boost converter voltage sensor signal line and detects the following malfunctions.

The MG ECU monitors the boost converter voltage (VL) sensor circuit. If the MG ECU detects an open or short circuit malfunction of the VL sensor circuit, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

Refer to the description for DTC P0AE6-225. Refer to DESCRIPTION .

1. Refer to the description for DTC P0AE6-225. Refer to «DESCRIPTION»(ref-568755-S21648467212013072300000) .
2. This circuit uses the power management control ECU to monitor the system main relays and stops the system if a malfunction is detected in the relays, because it may be impossible to shut off the high-voltage system if any of the relays becomes stuck.

Refer to the description for DTC P0AE6-225. Refer to DESCRIPTION .

The power management control ECU monitors the battery smart unit and detects insulation malfunctions in the high-voltage system.

HINT

1. *1: INF code 526 is stored together with P0AA6.
2. If DTC P0AA6 is stored, the vehicle cannot start.
3. When measuring insulation resistance using a megohmmeter, measure the resistance while jiggling the high voltage wire harness.

Scheme 497

TEXT IN ILLUSTRATION

SYSTEM DESCRIPTION

HINT

If a decrease in insulation resistance cannot be confirmed using a megohmmeter, check the Short Wave Highest Val in the Data List.

1. Characteristics of Short Wave Highest Value The Data List item Short Wave Highest Val and insulation resistance have the relationship shown in the table below. Short Wave Highest Val decreases with a decrease in insulation resistance. However, in some cases, even though the insulation resistance of the vehicle is normal, Short Wave Highest Val may decrease. Therefore, check Short Wave Highest Val while considering the following. Do not check until approximately 1 minute has passed after the power switch is turned on (IG) (*1). Do not check when there is a difference between the system voltages (HV battery voltage, VL-Voltage before boosting, and VH-Voltage after boosting) (*2). Short Wave Highest Value Trouble Area Neither condition (*1) nor (*2) is met and Short Wave Highest Val is approximately 0 V Since the insulation resistance is close to 0 ohms, there is a strong possibility of interference with a metal object. Neither condition (*1) nor (*2) is met and Short Wave Highest Val is between 0 and 5 V Since the insulation resistance is several hundred kiloohms, there is a strong possibility of the presence of fluid such as coolant.
2. How to Determine Part with Insulation Malfunction Jiggle the high-voltage wire harness to check if the resistance to body ground changes with the position of the wire harness or force applied. Repeat rotating and stopping of the MG1, MG2 and compressor with motor. Check that the Short Wave Highest Val does not decrease (for example if the motor stops with foreign matter forming a leak path) when the motor stops, or that the Short Wave Highest Val does not return to normal (for example if foreign matter moves away from the leak path) when the motor rotates. Increase the temperature of MG1and MG2. Check if the Short Wave Highest Val decreases with the temperature increase.

The power management control ECU monitors the insulation monitoring circuit located in the battery smart unit and detects a malfunction.

The power management control ECU (HV CPU) detects malfunctions of the battery current sensor by monitoring MG1 and MG2 torque. If the power management control ECU (HV CPU) detects a battery current sensor malfunction, the power management control ECU (HV CPU) will illuminate the MIL and set a DTC.

Refer to the description for DTC P0AE6-225. Refer to DESCRIPTION .

Refer to the description for DTC P0AE6-225. Refer to DESCRIPTION .

Refer to the description for DTC P0AE6-225. Refer to DESCRIPTION .

Refer to the description for DTC P0AE6-225. Refer to DESCRIPTION .

Refer to the description for DTC P0AE6-225. Refer to DESCRIPTION .

The SMRs (System Main Relays) are the relays that connect or disconnect the high voltage power system in accordance with commands from the power management control ECU.

There are 3 SMRs and 1 precharge resistor. SMRB, SMRP, SMRG, and the precharge resistor are located in the HV battery junction block assembly in the HV battery pack.

To connect to the high voltage power system, the vehicle will first turn on SMRP and SMRB to charge the vehicle through the system main resistor. Then, SMRP will be turned off after SMRG is turned on. To shut off the high voltage power system, SMRB and SMRG are turned off.

Scheme 498

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• COMPONENTS