Hybrid Battery Control System (Diagnostics - Introduction) (Plug-In): Other Toyota Prius Plug-in

DEFINITION OF TERMS

Scheme 1006

Scheme 1007

Scheme 1008

Scheme 1009

Scheme 1010

Scheme 1011

Scheme 1012

Scheme 1013

Scheme 1014

Scheme 1015

Scheme 1016

Scheme 1017

Scheme 1018

Scheme 1019

Scheme 1020

1. FUNCTION OF MAIN COMPONENTS The main components of the plug-in charge control system have the following functions: Component Function Plugin Charge Control ECU Assembly Controls the electric vehicle charger to perform plug-in charging, based on the signals from switches, charging current and charging voltage. Illuminates the charging indicator during plug-in charging. Electrical Vehicle Charger Assembly Converts the AC power supplied from the external outlet to DC power, boosts it to the battery voltage and supplies it to the HV battery. Power Management Control ECU Turns on the SMR (System Main Relay) after receiving the plug-in charge enable signal from the plugin charge control ECU assembly. HV Battery Assembly Stores the power supplied from the external outlet via plug-in charging. Hybrid Battery Junction Block Assembly Charging Relay Based on the signals sent from the plugin charge control ECU assembly, connects or disconnects the HV battery and the electric vehicle charger. Charging Cable (Electric Vehicle Charger Cable Assembly) Charging Connector Connects to the charging inlet (electric vehicle charger cable) and supplies power from an external outlet to the vehicle. Charging Circuit Interrupting Device (CCID) Stops the power supplied from the external outlet if an electric leak is detected on the vehicle. When normal conditions are detected and the reset button is pressed, power supply is resumed. Charging Inlet (Electric Vehicle Charger Cable) Connects to the charging connector on the charging cable (electric vehicle charger cable assembly) and supplies the power from the external outlet to the vehicle. Charging Indicator Illuminates, flashes or turns off to inform the user of the plug-in charging state of the HV battery. Charging Port Lid Switch Transmits the open/close signal from the charging port lid (battery charger connector opening lid sub-assembly) to the plugin charge control ECU assembly. Charging Inlet Light (Spot Light Assembly) Illuminates the charging inlet. Charging Timer Switch (Satellite Switch Set) Sets the plug-in charge timer start time and finish time. ECM Performs control of the engine in accordance with the target engine speed and required engine motive force received from the power management control ECU. Transmits various engine operating condition signals to the power management control ECU. Combination Meter Assembly Charging Timer Indicator Illuminates to indicate that the plug-in charge timer is set. EV Drive Mode Indicator Light Indicates that the vehicle is in EV mode. Multi-information Display The charge timer schedule display shows the plug-in charge scheduled starting time and finishing time. The plug-in effect display shows the amount of CO 2 reduced due to the plug-in system. The EV driving ratio display shows the ratio of distance driven in EV mode to HV mode. The energy monitor indicates the plug-in charging state. Displays messages according to system malfunction conditions. Receives the signal regarding the amount of charged electricity from the plugin charge control ECU assembly.
2. SYSTEM CONTROL Control List The plug-in charge control system consists of the controls listed below: Control Outline Charging Control The plugin charge control ECU assembly controls charging to either normal charging (maximum power) or slow charging (lower power) according to the State Of Charge of the HV battery. Normal charging is performed first, then, when the HV battery State Of Charge is nearing the fully charged state, the ECU assembly switches to slow charging. AC Input Control The plugin charge control ECU assembly detects the allowable current value via the CPLT signals and transmits the AC input current restriction value request signal (ILMT) to the electric vehicle charger. Auxiliary Control When charging, the auxiliary battery voltage is lowered to the limit of the control range (13.5 V) in order to reduce the current applied to the accessories and auxiliary battery. Charging Timer Function The electric vehicle charge is controlled to start supplying power from the external outlet at the start time set using the charging timer switch (satellite switch set) or to complete charging at the set finish time. Remote Air Conditioning Control The plugin charge control ECU assembly receives remote air conditioning signals from the power management control ECU. If the SOC is above a predetermined level, the plugin charge control ECU assembly transmits an output power signal to the electric vehicle charger assembly based on the AC input voltage signals. The electric vehicle charger assembly receives this signal and supplies power to the A/C inverter.
3. OPERATING CONDITION After turning the power switch off, the plugin charge control ECU assembly transmits a charge start request signal to the Charging Circuit Interrupting Device (CCID) and electric vehicle charger assembly by connecting the electric vehicle charger cable assembly to the charge inlet. The plugin charge control ECU assembly receives charge enable signals from CCID and the electric vehicle charger assembly and drives the electric vehicle charger assembly, charge relay, SMR, DC-DC converter and charges the HV battery pack with HV battery voltage that has been boosted by the electric vehicle charger assembly.
4. FUNCTION Plugin Charge Control ECU Assembly The plugin charge control ECU assembly controls the plug-in charge control system based on information sent from the electric vehicle charger assembly, such as charger operation condition, output current, output voltage and input voltage. The plugin charge control ECU assembly also controls the charging timer function, which enables the plug-in charging operation start time or finish time to be set. When the power switch is turned off and the charging cable (electric vehicle charger cable assembly) is connected to the charging inlet (electric vehicle charger cable), the plugin charge control ECU assembly transmits a charge start request signal to the Charging Circuit Interrupting Device (CCID) and electric vehicle charger assembly. After receiving a plug-in charging operation enable signal from the Charging Circuit Interrupting Device (CCID) and electric vehicle charger assembly, the plugin charge control ECU assembly activates the electric vehicle charger assembly, charging relay, and SMR (system main relay). The electric vehicle charger assembly outputs power, charging the HV battery. At this time, the charging indicator displays the HV battery charging state.
5. CONSTRUCTION Electric Vehicle Charger Assembly The case of the electric vehicle charger assembly is made of aluminum. This in conjunction with cooling fins and cooling blowers ensures heat radiation performance. TEXT IN ILLUSTRATION *1 Electric Vehicle Charger Assembly *2 Cooling Blower The electric vehicle charger assembly converts the AC power supplied from the external outlet to DC power, boosts it to the HV battery voltage and charges the HV battery. The plugin charge control ECU assembly actuates and stops the electric vehicle charger assembly, and requests it to charge. The electric vehicle charger assembly changes the AC 120 V*1 or AC 208 to 240 V*2 input power from the external power source to DC power and boosts it to the HV battery voltage. It then outputs it at 1.2 kW*1 or 2 kW*2 respectively. *1: When charging via a home outlet using the charging cable (electric vehicle charger cable assembly). *2: When charging at a charging station. The electric vehicle charger assembly has self-protection functions, such as over voltage protection, over current protection and over heat protection, so it will stop automatically and regulate the power, if needed. It also sends information about operating conditions to the plugin charge control ECU assembly. Using an air-cooling method which employs the built-in cooling fan, temperature increases due to the electric vehicle charger assembly operation will be reduced. Charging Cable (Electric Vehicle Charger Cable Assembly) The charging cable (electric vehicle charger cable assembly) consists of a charging connector, Charging Circuit Interrupting Device (CCID) and plug. TEXT IN ILLUSTRATION *1 Charging Inlet (Electric Vehicle Charger Cable) *2 Charging Connector *3 Charging Cable (Electric Vehicle Charger Cable Assembly) *4 Charging Circuit Interrupting Device (CCID) *5 AC Electrical Power - - When the charging connector is connected to the charging inlet (electric vehicle charger cable), it starts supplying electrical power from the external power source to the vehicle. The micro switch that detects the connecting condition of the charging connector and charging inlet (electric vehicle charger cable assembly) is built into it, and it transmits the connection condition to the plugin charge control ECU assembly. WARNING: Keep the connecting portion of the charging connector clear of foreign matter. If any foreign matter is present, problems may result such as an increase in charging time. Charging Circuit Interrupting Device (CCID) The CCID monitors electrical leakage while the vehicle is being charged from an external power source. If leakage or other problems are found, the built-in relay will cut off the power supply. The power indicator turns on while being connected to a 120 V outlet, and the error warning indicator will turn on if problems, such as a malfunction in which the built-in relay is forced to turn off, are detected. TEXT IN ILLUSTRATION *1 Power Indicator *2 Error Warning Indicator *3 Test Button *4 Reset Button CCID FUNCTIONS Item Function Leakage Detection and Power Cut-off Electrical leakage will be detected through charging, and the 2 built-in relays will cut off the power supply. Functionality Check The leakage detection and power cut-off function can be checked in advance of charging by operating the test button manually. Control Pilot Circuit (CPLT) Transmits information about the state of the CCID to the plugin charge control ECU assembly. Self Protection A built-in protection circuit will be operated to protect from unexpected external factors such as lightning. RESUMING BUILT-IN RELAY Condition Resuming method The relay turns off due to malfunctions, such as improper connection of the hybrid system, electric vehicle charger assembly or charging cable (electric vehicle charger cable assembly). Reconnect the charging cable (electric vehicle charger cable assembly) to the external power source. The relay turns off due to a leakage detected in the high-voltage circuit. Repair the leakage, and then reconnect the system to the external power source, or operate the reset button. Charging Relay The charging relay is integrated in the hybrid vehicle junction block assembly. During plug-in charging, based on signals from the plugin charge control ECU assembly, the charging relay opens or closes the circuit that supplies the power from the electric vehicle charger assembly to the HV battery. TEXT IN ILLUSTRATION *1 Hybrid Vehicle Junction Block Assembly *2 Charging Relay (CHRB) *3 Charging Relay (CHRG) - - Front - - Charging Indicator The plugin charge control ECU assembly illuminates, flashes or turns off the charging indicator to inform the user of the battery charging state. TEXT IN ILLUSTRATION *1 Charging Indicator - - CHARGING INDICATOR OPERATING CONDITIONS Operation Condition Illuminate Plug-in charging from an external power source. The remote climate control system for plug-in HV is operating. Flash The plugin charge control ECU assembly has detected an abnormality. Charging is not conducted in this case. Off Charging has completed normally. The specified amount of time has elapsed after detecting an abnormality. Charging Timer Switch (Satellite Switch Set) The charging timer switch (satellite switch set) is a momentary type switch. By pressing this switch, the charging operation start time or finish time can be set. The set time is displayed on the multi-information display. The timer function can be reset.
6. SYSTEM DIAGRAM

CHECK FOR INTERMITTENT PROBLEMS

1. CHECK FOR INTERMITTENT PROBLEMS Perform a simulation test. Refer to «HOW TO PROCEED WITH TROUBLESHOOTING»(ref-553290-S23053163842013051700000) . Reproduce the plug-in charging status when a malfunction occurred based on the interview sheet, freeze frame data recorded when the DTC was stored and freeze frame data recorded in Charge Cancel History. Check the connector(s) and terminal(s). Refer to «ELECTRONIC CIRCUIT INSPECTION PROCEDURE»(ref-553290-S25504548052013051700000) . Wiggle the harness and connector(s). Refer to «HOW TO PROCEED WITH TROUBLESHOOTING»(ref-553290-S23053163842013051700000) . Heat or cool suspected parts. Refer to «HOW TO PROCEED WITH TROUBLESHOOTING»(ref-553290-S23053163842013051700000) .

Scheme 1021

1. CHARGE CANCEL HISTORY NOTE: This function shows the reason/cause of plug-in charging failures. If plug-in charging is cancelled, delayed or interrupted due to a cause other than a vehicle malfunction (no DTC output), the cause is memorized in the "Charge Cancel History". According to the items in the following table, the freeze frame data and accumulated total of occurrences are recorded in the Charge Cancel History when charging fails. HINT: When an item is memorized in the Charge Cancel History, the next time the power switch is turned on (IG) a message is displayed on the multi-information display as "CHARGE RESULT:". Reading the freeze frame data that is recorded at the time when a charging failure occurs helps determine the cause of plug-in charging failure (canceled, delayed, etc.). Connect the Techstream to the DLC3. Turn the power switch on (IG). Enter the following menus: Powertrain / Plug-in Control / Utility / Charge Cancel History. Referring to the following table, confirm the "Charge Cancel History". USER OPERATION (CONNECTOR RELATED) Tester Display [Multi Information Display] Accumulated total memory Memorization Condition Possible Cause Action to be Taken Charges Canceled (Charge Connector Not Engaged Properly) [CHARGE STOPPED DUE TO CHARGE CONNECTOR OPERATION] Stored During plug-in charging, the latch release button on the charging connector is pressed longer than a certain period of time before the HV battery becomes fully charged. Vehicle Service life of engagement parts on the charging connector or charging inlet Inspect the charging cable. Refer to «INSPECTION»(ref-553291-S11981131972013051700000) PISW circuit malfunction (open/short) Check PISW signal circuit. Refer to «DIAGNOSTIC TROUBLE CODE CHART»(ref-553450-S09149149242013051700000) User Charging connector connection not secured properly Latch release button pressed too long (misoperation) Interview customer and provide instruction on usage Charges Canceled (Power Failure) [CHARGE STOPPED DUE TO OUTAGE OR PLUG REMOVE] Stored During plug-in charging, AC power is cut off (including voltage drop) or CPLT (control pilot signal) cannot be received with the charging cable correctly connected. Vehicle Charging cable internal malfunction Inspect the charging cable. Refer to «ON-VEHICLE INSPECTION»(ref-553291-S00802399512013051700000) CPLT (control pilot signal) circuit malfunction (open/short) Check Control Pilot Signal Circuit. Refer to «Control Pilot Signal Circuit»(ref-553461-S20517010842013051700000) Charging environment Plug disconnected Power outage Interview customer and provide instruction on usage Charging station self-diagnosis error Check the charging station Charge with the charging cable provided with the vehicle User Charging connector disconnected Interview customer and provide instruction on usage CHARGING CABLE/CHARGING EQUIPMENT Tester Display [Multi Information Display] Accumulated total memory Memorization Condition Possible Cause Action to be Taken Charges Canceled (AC Line) [CHARGE STOPPED DUE TO CHARGE CABLE OR OTHER] - AC voltage is not output for a certain period of time even though the charging cable is connected correctly and CPLT (control pilot signal) is generated. Vehicle Open in the AC line between the electric vehicle charger assembly and electric vehicle charger cable Open in the AC line in the charging cable Check AC line (Electric vehicle charger assembly - Electric vehicle charger cable). Refer to «DIAGNOSTIC TROUBLE CODE CHART»(ref-553450-S09149149242013051700000) Inspect the charging cable Charging environment Open in the AC line in the charging station Check charging station Charge with the charging cable provided with the vehicle Charges Canceled (CCID Relay) [CHARGE STOPPED DUE TO CHARGE CABLE OR OTHER] - AC voltage is applied to the electric vehicle charger assembly for a certain period of time before the charging cable CCID relay is closed. Vehicle Charging cable CCID relay is stuck closed Inspect the charging cable. Refer to «ON-VEHICLE INSPECTION»(ref-553291-S00802399512013051700000) Charging environment Charging station CCID relay is stuck closed Check charging station Charge with the charging cable provided with the vehicle Charges Canceled (Nonstandard Cable) [CHARGE STOPPED DUE TO CHARGE CABLE OR OTHER] - Non-standard CPLT (control pilot signal) pulse received for a certain number of times or non-standard duty received. Vehicle Charging cable malfunction Inspect the charging cable. Refer to «ON-VEHICLE INSPECTION»(ref-553291-S00802399512013051700000) Charging environment Incompatible with charging station used Check charging station Charge with the charging cable provided with the vehicle OTHER Tester Display [Multi Information Display] Accumulated total memory Memorization Condition Possible Cause Action to be Taken Charges Canceled (Battery Temperature) [CHARGE COMPLETE (RESTRICTED DUE TO BATT. TEMP.)] Stored HV battery temperature is too high and SOC is too low when charging completed Charging environment Drop in SOC at full charge due to extremely hot HV battery Explain to the customer that SOC at full charge drops if the HV battery is too hot Charges Canceled (Rated Electricity Power Supply) [CHARGE STOPPED DUE TO INSUFF. POWER SUPPLY] - AC power voltage is not as specified or 120 V outlet charge power decreased due to AC line circuit impedance, etc. Vehicle AC voltage sensor (VAC sensor) malfunction Check VAC sensor. Refer to «DIAGNOSTIC TROUBLE CODE CHART»(ref-553450-S09149149242013051700000) Charging environment Decrease in 120 V outlet charge power from the infrastructure side System voltage decreased due to use of a multi-outlet or an extension cord Interview customer and provide instruction on usage Charges Canceled (+B) [CHARGE STOPPED TO PROTECT BATTERY DUE TO HI ELEC. CONSUMP.] Stored During plug-in charging, HV battery charge power drops and low SOC is detected. Vehicle Discharged auxiliary battery Turn the power switch on (READY) and leave the vehicle for 15 min (to charge the auxiliary battery) Explain to the customer that the auxiliary battery will discharge when the vehicle is left without being started for a long time. Inspect auxiliary battery. Refer to «ON-VEHICLE INSPECTION»(ref-553425-S27331008952013051700000) User SOC dropped because auxiliary power consumption increased due to the use of accessories or turning the power switch on (IG) Explain to the customer to minimize auxiliary power consumption during plug-in charging Charges Canceled (System) [ - ] - System malfunction is detected if plug-in charging status cannot be switched to start or the auxiliary battery is discharged (including large auxiliary load). Vehicle Discharged auxiliary battery Inspect auxiliary battery. Refer to «ON-VEHICLE INSPECTION»(ref-553425-S27331008952013051700000) DELAYED Tester Display [Multi Information Display] Accumulated total memory Memorization Condition Possible Cause Action to be Taken Charges Delayed (Charge Control Value Low) [ - ] Stored During plug-in charging, WIN (charge control value) remains low for a certain period of time. Charging environment WIN (charge control value) decreased due to extremely low or high temperature environment Explain to the customer that charge time may be longer depending on ambient temperature Charges Delayed (+B) [ - ] Stored When charge power being monitored is compared to outlet charge power from the electric vehicle charger assembly, auxiliary power consumption exceeding the allowable auxiliary power consumption is detected. User Charge power dropped because auxiliary power consumption increased due to the use of accessories or turning the power switch on (IG) Explain to the customer to minimize auxiliary power consumption during plug-in charging Charges Delayed (Charger Output Low) [ - ] Stored Outlet charge power remains constant for a certain period of time when target charge power is constant. Vehicle Electric vehicle charger assembly internal thermistor malfunction Replace Electric vehicle charger assembly. Refer to «COMPONENTS»(ref-553291-S32053222832013051700000) Charging environment Electric vehicle charger assembly output limitations in extremely hot environments System voltage decreased due to use of a multi-outlet or an extension cord Interview customer and provide instruction on usage
2. Charge Cancel History Freeze Frame Data HINT: Up to three of the most recent data for each "Charge Cancel History" group (user operation (connector related), charging cable/charging equipment, others, and delay) is recorded as freeze frame data. The latest "Charge Cancel History" freeze frame data can record data at the time a charging failure is detected as well as up to 3 seconds from that point. Freeze frame data is useful when performing troubleshooting or interviewing a customer because the plug-in charging failure condition (canceled, delayed, etc.) and user operation condition can be accurately confirmed by reading it. It can also be useful when performing a reproduction test. With the latest "Charge Cancel History" freeze frame data, the charging failure detection point changes between point 3 and 4 depending on the conditions. Connect the Techstream to the DLC3. Turn the power switch on (IG). Enter the following menus: Powertrain / Plug-in Control / Utility / Charge Cancel History. Select "Charge Cancel History" to display the freeze frame data for the time a plug-in charge failure (canceled, delayed, etc.) occurred. Check the freeze frame Data recorded with the Charge Cancel History. CHARGE CANCEL HISTORY FREEZE FRAME DATA Tester Display Measurement Item/Range Normal Condition Diagnostic Note Charging Control Status Charge control status/ 0, 1, 2, 3 or 4 0: Initial state 1: Start 2: Charging 3: Interrupted 4: End Progress of charging sequence can be checked. On-Board Charger Input Voltage Effective AC voltage (VAC sensor value) input to the electric vehicle charger assembly from the charging inlet/ V Almost the same as rated voltage Whether input voltage was too low or the voltage output from the electric vehicle charger assembly was too low (due to boost circuit malfunction, etc.) can be checked. The VAC sensor is located inside the electric vehicle charger assembly and sends a signal to the plugin charge control ECU assembly via the electric vehicle charger assembly. On-Board Charger Stopping Input Voltage Effective AC voltage (VAC sensor value) input to the electric vehicle charger assembly from the charging inlet when the charger is not operating/ V Almost the same as rated voltage - Rated Electricity Power Supply Rated power for charging when the electric vehicle charger cable assembly is connected/ kW 1.44 kW: Rated power AC 100 V 2.00 kW: Rated power AC 200 V The rated power appropriate for the capacity of the electric vehicle charger assembly is set based on the AC voltage and rated amperage. Current Upper Limit Value Upper limit of amperage which can be input from the EVSE (charging station)/ A - ILMT duty value requested by the plugin charge control ECU assembly to the electric vehicle charger assembly at the ILMT terminal. Charger Output Current Amperage (ICHG sensor value) output from the electric vehicle charger assembly/ A - The ICHG sensor is located inside the electric vehicle charger assembly and sends a signal to the plugin charge control ECU assembly via the electric vehicle charger assembly. Offset Value of Charger Output Current Offset value of amperage (ICHG sensor value) output from the electric vehicle charger assembly/ A - - Charger Output Voltage Voltage (VCHG sensor value) output from the electric vehicle charger assembly/ V - The VCHG sensor is located inside the electric vehicle charger assembly and sends a signal to the plugin charge control ECU assembly via the electric vehicle charger assembly. Auxiliary Battery Voltage Auxiliary battery voltage/ V 10.0 to 15.0 V: Always - SOC HV battery state of charge/ % 0.0 to 100.0%: Always - Battery Minimum Temperature HV battery minimum temperature/ °C - Low HV battery temperature may be the cause of charge time delay. Plug-in Charge Start Signal Power source condition of plug-in charge system/ ON or OFF ON: Power ON OFF: Power OFF An activation signal generated by the plugin charge control ECU assembly. Battery Current HV battery current/ A -170 to 230 A: Always HV battery current monitored by the power management control ECU. Battery Current (High Accuracy) HV battery current/ A -27 to 13 A: Plug-in charging HV battery current (high accuracy) monitored by the power management control ECU. Battery Voltage HV battery voltage/ V 168.0 to 229.6 V: Always HV battery voltage monitored by the power management control ECU. On-Board Charger Status Electric vehicle charger assembly charging condition/ 0, 1 or 2 0: Stand-by 1: Ready 2: Abnormal interruption Signals are input from the electric vehicle charger assembly to the plugin charge control ECU assembly. The status of the signal has 3 patterns; Stand-by, Ready and Abnormal interruption Normal Charging Complete Status Normal charging completion state/ Incomp or Complete Incomp: Normal charging not complete Complete: Normal charging complete - Push Charging Complete Status Push charging completion state/ Incomp or Complete Incomp: Push charging not complete Complete: Push charging complete - CPLT Duty Ratio Duty value of CPLT signal generated at the electric vehicle charger cable assembly side (including EVSE (charging station))/ % - Whether the amperage was limited to the needs of EVSE (charging station)) can be checked. Allowable amperage from EVSE (charging station) can be determined based on CPLT duty. (Allowable amperage [A] = CPLT duty value x 0.6) The plugin charge control ECU assembly commands the electric vehicle charger assembly to limit the amperage (ILMT, etc.) based on CPLT duty value, however the allowable amperage is not exactly the same as the value obtained using the above formula. CPLT Pulse Time Duration of 1 cycle of CPLT/ μs 980 to 1020 μs: CPLT (control pilot signal) generated Whether a non-standard cable was used can be checked. CPLT Status Generation of CPLT (control pilot signal)/ ON or OFF ON: CPLT (control pilot signal) generated ON: CPLT (control pilot signal) not generated - Target Charge Power Charging power target value/ kW - - Request Charge Power Charging power command sent from the plugin charge control ECU assembly to the electric vehicle charger assembly/ kW 0.00 to 2.00 kW - Charge Control Value WIN (charge control value) of chargeable HV battery/ kW - Whether charging is limited by HV battery control can be checked. Positive value indicates charging. Charge Control Value Limit Charging WIN (charge control value) (HV battery side WIN (charge control value) + WIN (charge control value) when offset learning fails)/ kW - Whether charging is limited by HV battery control can be checked. Negatives value indicates charging. Request CCID Relay Connect CCID relay connection request/ ON or OFF OFF: CCID relay connection not requested ON: CCID relay connection requested - SMR Status SMR connection state/ Uncnnct or Connect Uncnnct: SMR OFF Connect: SMR ON - Request CHRB Connect CHRB relay connection request/ ON or OFF OFF: CHRB relay open requested ON: CHRB relay close requested Request sent to CHRB relay excitation cable Request CHRG Connect CHRG relay connection request/ ON or OFF OFF: CHRG relay open requested ON: CHRG relay close requested Request sent to CHRG relay excitation cable Charge Cable Inserted Electric vehicle charger cable assembly insertion condition without considering ON/OFF of the latch release button (PI switch)/ ON or OFF OFF: Electric vehicle charger cable assembly not inserted ON: Electric vehicle charger cable assembly inserted Connection condition, open, connection failure, etc. of the electric vehicle charger cable assembly can be checked. Charge Cable Engaged Electric vehicle charger cable assembly latch release button (PI switch) condition/ ON or OFF OFF: Latch release button (PI switch) engaged when electric vehicle charger cable assembly inserted ON: Latch release button (PI switch) released when electric vehicle charger cable assembly inserted Connection condition, open, connection failure, etc. of the electric vehicle charger cable assembly can be checked. Request On-Board Charger Start Electric vehicle charger assembly activation request/ ON or OFF OFF: Electric vehicle charger assembly deactivation requested ON: Electric vehicle charger assembly activation requested - Charger Gate Request CHEN signal (electric vehicle charger gate open/close) request/ Close or Open Close: Electric vehicle charger gate close requested Open: Electric vehicle charger gate open requested - Charging Permit Status Charging permission status/ ON or OFF - - Charge Power Request Capability Status Charge power request transmission status/ NG or OK - - Charging Time Plug-in charging time/ min - - Charging Suspended Time Duration of plug-in charging temporary cancellation/ s - - IG Status IG condition/ ON or OFF OFF: IG OFF ON: IG ON - A/C Inverter Gate Status A/C inverter gate status/ ON or OFF OFF: A/C inverter gate not operating ON: A/C inverter gate operating - Remote A/C Request Remote air conditioning system request status/ ON or OFF OFF: Remote air conditioning system not requested ON: Remote air conditioning system requested - Request DC/DC Converter Stop Hybrid vehicle converter prohibition signal/ ON or OFF OFF: Not requested ON: Requested - Auxiliary Battery Low after DC/DC Converter Stop Drop in auxiliary battery SOC after the hybrid vehicle converter stops operating/ ON or OFF OFF: Did not drop ON: Dropped - Request Current Sensor Offset Learning Current sensor offset learning request/ ON or OFF OFF: Not requested ON: Requested

FREEZE FRAME DATA

1. FREEZE FRAME DATA HINT: The plugin charge control ECU assembly records vehicle and driving condition information as freeze frame data the moment a DTC is stored. Freeze frame data is used to determine the condition of the vehicle at the time the malfunction occurred and to perform a reproduction test. When checking the information codes for the plug-in charge control system, refer to Detail Code 1 to 5. Connect the Techstream to the DLC3. Turn the power switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / Plug-in Control / Trouble Codes. Select a DTC in order to display its freeze frame data. Check the freeze frame information recorded with the DTC. FREEZE FRAME DATA Tester Display Measurement Item/Range Normal Condition Charge Mode Charge mode/ Min.:-128, Max.: 127 0: Not charging 2: Charging Charging Control Status Charge control status/ Min.:-128, Max.: 127 0: Initial state 1: Start 2: Charging 3: Interrupted 4: End Diagnostic Note: Progress of charging sequence can be checked. Plug-in Charge Start Signal Power source condition of plug-in charge system/ ON or OFF ON: Power ON OFF: Power OFF Diagnostic Note: An activation signal generated by the plugin charge control ECU assembly. HV Control Status HV system control mode (driving/charging)/ Min.:-128, Max.: 127 0: Unconfirmed (initial state) 1: Normal (driving) mode 2: Plug-in (charging) mode Diagnostic Note: Whether the vehicle was being plug-in charged or driven (parked) can be checked. On-Board Charger Input Voltage Effective AC voltage (VAC sensor value) input to the electric vehicle charger assembly from the charging inlet/ Min.: 0.0 V, Max.: 6553.5 V Almost the same as rated voltage Diagnostic Note: Whether input voltage was too low or the voltage output from the electric vehicle charger assembly was too low (due to boost circuit malfunction, etc.) can be checked. If 270 V or more is shown, there is a possibility that the charging voltage was higher than standard voltage, causing a DTC to be output. The VAC sensor is located inside the electric vehicle charger assembly and sends a signal to the plugin charge control ECU assembly via the electric vehicle charger assembly. On-Board Charger Input Voltage Sensor Offset Displays offset value of the VAC sensor input voltage (AC voltage) sent from the electric vehicle charger cable assembly to the electric vehicle charger assembly. Min.:-500 V, Max.: 500 V - Diagnostic Note: Offset amount of the VAC sensor input voltage (AC voltage) sent to the electric vehicle charger assembly can be judged. The VAC sensor is located inside the electric vehicle charger assembly and sends a signal to the plugin charge control ECU assembly via the electric vehicle charger assembly. Rated Electricity Power Supply Rated power for charging when the electric vehicle charger cable assembly is connected/ Min.:-328.00 kW, Max.: 327.67 kW 1.44 kW: Rated power AC 100 V 2.00 kW: Rated power AC 200 V Diagnostic Note: The rated power appropriate for the capacity of the electric vehicle charger assembly is set based on the AC voltage and rated amperage. The rated power of the cable (or charging station) used for charging can be checked. (Whether the charging problem (delay, unable to charge, etc.) was due to a misunderstanding of the customer can be confirmed as the charging time differs when the vehicle is charged at 200 V or 100 V.) Charger Output Current Amperage (ICHG sensor value) output from the electric vehicle charger assembly/ Min.:-125.000 A, Max.: 124.996 A - Diagnostic Note: The ICHG sensor is located inside the electric vehicle charger assembly and sends a signal to the plugin charge control ECU assembly via the electric vehicle charger assembly. On-Board Charger Current Sensor Voltage Output voltage of the ICHG sensor based on the amperage output from the electric vehicle charger assembly/ Min.: 0.00 V, Max.: 79.99 V 1.64 to 2.36 V: Power switch on (IG), electric vehicle charger cable assembly not connected 1.64 to 7.00 V: Plug-in charging Diagnostic Note: The ICHG sensor is located inside the electric vehicle charger assembly and sends a signal to the plugin charge control ECU assembly via the electric vehicle charger assembly. Charger Output Voltage Voltage (VCHG sensor value) output from the electric vehicle charger assembly/ Min.: 0.0 V, Max.: 32767.5 V - Diagnostic Note: The VCHG sensor is located inside the electric vehicle charger assembly and sends a signal to the plugin charge control ECU assembly via the electric vehicle charger assembly. On-Board Charger Voltage Sensor Voltage Output voltage of the VCHG sensor based on the voltage output from the electric vehicle charger assembly/ Min.: 0.00 V, Max.: 79.99 V 1.72 to 2.22 V: Power switch on (IG), electric vehicle charger cable assembly not connected 1.72 to 6.00 V: Plug-in charging Diagnostic Note: The VCHG sensor is located inside the electric vehicle charger assembly and sends a signal to the plugin charge control ECU assembly via the electric vehicle charger assembly. +B Auxiliary battery voltage/ Min.: 0.000 V, Max.: 65.535 V Constant: 10.0 to 15.0 V Diagnostic Note: Condition of the auxiliary battery (voltage drop, etc.) during charging can be checked. State of Charge (All Bat) HV battery state of charge/ Min.: 0.0%, Max.: 100.0% Constant: 0.0 to 100.0% Diagnostic Note: Signals are sent from the power management control ECU to the plugin charge control ECU assembly via CAN communication. Plug-in Charging Request Continuous charging status/ ON or OFF ON: Continuous charging OFF: Other than continuous charging Diagnostic Note: ON is displayed if continuous charging was started. This indicates the control status inside the plugin charge control ECU assembly. If this item is displayed as ON, charging was almost complete. CPLT Duty Ratio Duty value of CPLT signal generated at the electric vehicle charger cable assembly side (including EVSE (charging station))/ Min.: 0.0 %, Max.: 127.5 % 0.0 to 100.0 % Diagnostic Note: Whether the amperage was limited to the needs of EVSE (charging station) can be checked. Allowable amperage from EVSE (charging station) can be determined based on CPLT duty. (Allowable amperage [A] = CPLT duty value x 0.6) The plugin charge control ECU assembly commands the electric vehicle charger assembly to limit the amperage (ILMT, etc.) based on CPLT duty value, however the allowable amperage is not exactly the same as the value obtained using the above formula. CPLT Pulse Time Duration of 1 cycle of CPLT/ Min.: 0 μs, Max.: 65535 μs 980 to 1020 μs: CPLT (control pilot signal) generated Diagnostic Note: Whether a non-standard cable was used can be checked. CPLT Output Voltage CPLT terminal voltage/ Min.: 0.0 V, Max.: 25.5 V 8 to 10 V: Connected, not ready to receive power 5 to 7 V: Connected, ready to receive power, indoor charging ventilation not required 3 V: Connected, ready to receive power, indoor charging ventilation required 0 V: Not connected to the EVSE (charging station) system or power unavailable Diagnostic Note: Charging condition can be determined. Charge Request to Charger Electric vehicle charger assembly activation request/ ON or OFF ON: Electric vehicle charger assembly activation requested OFF: Electric vehicle charger assembly deactivation requested Current Upper Limit Value Upper limit of amperage which can be input from the EVSE (charging station)/ Min.:-328.00 A, Max.: 327.67 A - Diagnostic Note: ILMT duty value requested by the plugin charge control ECU assembly to the electric vehicle charger assembly at the ILMT terminal. AC Upper Limit Duty ILMT duty value/ Min.: 0.0 %, Max.: 127.5 % 0.0 to 100.0 % Charger State Pulse Duty Ratio Electric vehicle charger assembly charging status indicated by duty/ Min.: 0.0 %, Max.: 127.5 % 0.0 to 38.0 %: Stand-by 38.0 to 65.0 %: Ready 65.0 to 100.0 %: Abnormal interruption Diagnostic Note: Signals are input from the electric vehicle charger assembly to the plugin charge control ECU assembly. The status of the signal has 3 patterns; Stand-by, Ready and Abnormal interruption Charger State Pulse Time Duration of 1 cycle of Charger State Pulse Duty Ratio/ Min.: 0 ms, Max.: 65535 ms 97 to 103 ms Target Charge Power Charging power target value/ Min.:-328.00 kW, Max.: 327.67 kW - Request Charge Power Charging power command sent from the plugin charge control ECU assembly to the electric vehicle charger assembly/ Min.:-328.00 kW, Max.: 327.67 kW 0.00 to 2.00 kW Diagnostic Note: (Charging power) = (Target charging power) + (Compensation value) However, the charging power is limited between the upper and lower limits. Request Charge Power Duty Ratio Charging power duty value/ Min.: 0.0 %, Max.: 127.5 % 15.0 to 61.7 % Offset Value of Charge Power Request Charging power compensation value/ Min.:-328.00 kW, Max.: 327.67 kW - Calculated Value of Charge Power Input Calculated value of monitoring power at the HV battery/ Min.:-328.00 kW, Max.: 327.67 kW - Calculated Value of Charge Power Output Calculated value of power supplied from the electric vehicle charger assembly/ Min.:-328.00 kW, Max.: 327.67 kW - CHRB Status CHRB relay status/ ON or OFF ON: CHRB relay closed OFF: CHRB relay open CHRG Status CHRG relay status/ ON or OFF ON: CHRG relay closed OFF: CHRG relay open CHRB Control Status Request sent to CHRB relay excitation cable/ ON or OFF ON: CHRB relay close requested OFF: CHRB relay open requested CHRG Control Status Request sent to CHRG relay excitation cable/ ON or OFF ON: CHRG relay close requested OFF: CHRG relay open requested Voltage with Charge Cable Connected PISW terminal voltage used for checking electric vehicle charger cable assembly connection condition/ Min.: 0.00 V, Max.: 79.99 V 1.2 to 1.8 V: Electric vehicle charger cable assembly connected 4.0 to 4.5 V: Electric vehicle charger cable assembly not connected 2.5 to 3.1 V: Electric vehicle charger cable assembly connected and the latch release button (PI switch) engaged Charge Cable Inserted Electric vehicle charger cable assembly insertion condition without considering ON/OFF of the latch release button (PI switch)/ ON or OFF ON: Electric vehicle charger cable assembly inserted OFF: Electric vehicle charger cable assembly not inserted Charge Cable Engaged Electric vehicle charger cable assembly latch release button (PI switch) condition/ ON or OFF ON: Latch release button (PI switch) released when electric vehicle charger cable assembly inserted OFF: Latch release button (PI switch) engaged when electric vehicle charger cable assembly inserted Charge Lid Turn Off Light Status Charging inlet light turn off request/ ON or OFF ON: Charging inlet light not illuminated OFF: Charging inlet light illuminated Diagnostic Note: A turn off request is sent when the electric vehicle charger cable assembly is connected or the power switch is turned on (READY). Check of the charging inlet light function can be performed together with checking the results of [Charge Cable Inserted] and [Charge Cable Engaged]. Charge Lid SW Charging port lid switch status/ ON or OFF ON: Charging port lid closed OFF: Charging port lid open States of Pre Air-Conditioner on Battery Remote climate control system operation condition/ ON or OFF ON: Remote climate control system operating OFF: Remote climate control system not operating Diagnostic Note: Used to determine the cause when charging cannot be performed. Charge Indicate Light Status Charging indicator illumination status/ Min.: 0, Max.: 255 0: Charging Indicator turned off 1: Charging Indicator blinking in short intervals 2: Charging indicator blinking in long intervals 3: Charging indicator illuminated Timer Lamp Light Request Charging timer indicator illumination status/ ON or OFF ON: Charging timer indicator illuminated OFF: Charging timer indicator not illuminated Charging Timer SW Charging timer switch condition/ ON or OFF ON: Charging timer switch operated OFF: Charging timer switch not operated DTC Clear Warm Up Number of times the engine is warmed up after clearing DTCs/ Min.: 0, Max.: 255 - Diagnostic Note: MIL OFF, engine coolant temperature increases from below 22°C (71.6°F) before starting the engine, to above 70°C (158°F) after starting the engine: Increases once DTC Clear Run Distance Drive distance after clearing DTCs/ Min.: 0 km (0 mile), Max.: 65535 km (40723 mile) - DTC Clear Min Elapsed time after clearing DTCs/ Min.: 0 min, Max.: 65535 min - Engine Coolant Temp Engine coolant temperature/ Min.:-40°C (-40°F), Max.: 140°C (284°F) Cold start-->Fully warmed up: Gradually rises After warming up: 80 to 100°C (176 to 212°F) Engine Revolution Engine speed/ Min.: 0 rpm, Max.: 16383 rpm While idling after the engine is warmed up and inspection mode: Approximately 1000 rpm While driving at a constant speed: No significant fluctuation Vehicle Spd Vehicle speed/ Min.: 0 km/h (0 mph), Max.: 255 km/h (158 mph) Vehicle stopped: 0 km/h (0 mph) While driving at a constant speed: No significant fluctuation Engine Run Time Elapsed time after starting engine/ Min.: 0 s, Max.: 65535 s - Diagnostic Note: Elapsed time after starting engine After the power switch is turned on (READY), elapsed time from initial engine start until the power switch is turned off. Calculate Load Calculated load/ Min.: 0.0%, Max.: 100.0% Engine idling with warm engine, air conditioner off, park (P) and inspection mode selected: 11.0 to 22.0 % Engine speed of 2500 rpm, air conditioner off, park (P) and inspection mode selected: 12.1 to 18.2 % Throttle Position Throttle position sensor/ Min.: 0.0%, Max.: 100.0% Throttle valve fully closed: 10.0 to 24.0% Num of Current Code The number of current DTCs/ Min.: 0, Max.: 255 - Num of History Code The number of history DTCs/ Min.: 0, Max.: 255 - Detail Code 1 Number of detailed information stored by information code/ Min.: 0, Max.: 32767 - Detail Code 2 Number of detailed information stored by information code/ Min.: 0, Max.: 32767 - Detail Code 3 Number of detailed information stored by information code/ Min.: 0, Max.: 32767 - Detail Code 4 Number of detailed information stored by information code/ Min.: 0, Max.: 32767 - Detail Code 5 Number of detailed information stored by information code/ Min.: 0, Max.: 32767