HYBRID / BATTERY CONTROL MOTOR GENERATOR CONTROL SYSTEM P0CA300 DC/DC Converter Step Up Voltage Performance
DTC SUMMARY
MALFUNCTION DESCRIPTION
This DTC indicates that it has been detected that the VH voltage cannot be boosted as commanded due to malfunction of the boost converter system. The cause of this malfunction may be one of the following:
Inverter with converter assembly internal circuit malfunction
The connectors are not connected properly
DESCRIPTION
The boost converter boosts the 207.2 V DC from the HV battery to a maximum of approximately 600 V DC. The inverter converts the voltage that has been boosted by the boost converter into alternating current, which is used for driving generator (MG1) and motor (MG2). When a motor or 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 207.2 V in order to charge the HV battery.
The motor generator control ECU (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 motor generator control ECU (MG ECU) controls the operation of the boost converter to boost the voltage to the target voltage.
| DTC No. | Detection Item | DTC Detection Condition | Trouble Area | MIL | Warning Indicate | Note |
|---|---|---|---|---|---|---|
| P0CA300 | DC/DC Converter Step Up Voltage Performance | Abnormal voltage execution value:
Boosting cannot be performed as requested due to a boost converter system malfunction. (1 trip detection logic) |
·
Wire harness or connector ·
Inverter with converter assembly |
Comes on | Master Warning:
Comes on |
SAE Code:
P0CA3 |
- HINT:
-
With the vehicle stopped, apply the parking brake and turn the ignition switch to ON (READY).
-
With the shift lever in P, depress the brake pedal firmly, and quickly and fully depress the accelerator pedal.
-
Immediately after the accelerator pedal is fully depressed, "VH-Voltage after boosting" will be between 400 and 600 V.
MONITOR DESCRIPTION
If the difference between the requested boost converter voltage and the actual boost converter voltage exceeds a predetermined value, the motor generator control ECU determines that there is a malfunction of the execution or monitoring of the boost converter voltage, and the ECU will illuminate the MIL and store a DTC.
MONITOR STRATEGY
| Related DTCs | P0CA3 (INF P0CA300): Discrepancy between commanded and actual voltage |
| Required sensors/components | Boost converter |
| Frequency of operation | Continuous |
| Duration | TMC's intellectual property |
| MIL operation | 1 driving cycle |
| Sequence of operation | None |
TYPICAL ENABLING CONDITIONS
| The monitor will run whenever the following DTCs are not stored | TMC's intellectual property |
| Other conditions belong to TMC's intellectual property | - |
TYPICAL MALFUNCTION THRESHOLDS
| TMC's intellectual property | - |
COMPONENT OPERATING RANGE
| Motor generator control ECU | DTC P0CA3 (INF P0CA300) is not detected |
CONFIRMATION DRIVING PATTERN
- HINT:
- ·
After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.
·When clearing the permanent DTCs, refer to the "CLEAR PERMANENT DTC" procedure.
Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
Turn the ignition switch off and wait for 2 minutes or more.
Turn the ignition switch to ON and wait for 5 seconds or more. [*1]
Turn the ignition switch to ON (READY) and wait for 5 seconds or more. [*2]
Press the HV EV CHG HOLD mode switch to enter HV drive mode. [*3]
Depress the accelerator pedal of the vehicle with the engine stopped and the shift lever in P to start the engine. [*4]
- NOTICE:
-
As the state of charge of the HV battery may be low after driving in fail-safe mode, it will automatically be charged for 5 to 10 minutes with ignition switch ON (READY) after repairs have been performed.
- HINT:
-
[*1] to [*4]: Normal judgment procedure.
-
The normal judgment procedure is used to complete DTC judgment and also used when clearing permanent DTCs.
Enter the following menus: Powertrain / Motor Generator / Utility / All Readiness.
Check the DTC judgment result.
- HINT:
- ·
If the judgment result shows NORMAL, the system is normal.
·If the judgment result shows ABNORMAL, the system has a malfunction.
·If the judgment result shows INCOMPLETE, perform the normal judgment procedure again.
CAUTION / NOTICE / HINT
- CAUTION:
-
Refer to the precautions before inspecting high voltage circuit.
- NOTICE:
- ·
After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.
·When disconnecting and reconnecting the auxiliary battery.
- HINT:
-
When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.
- HINT:
P0CA300 may be output as a result of the malfunction indicated by the DTCs in table below.
(a)The chart above is listed in inspection order of priority.
(b)Check DTCs that are output at the same time by following the listed order. (The main cause of the malfunction can be determined without performing unnecessary inspections.)
Table 1 Malfunction Content Relevant DTC Insulation malfunction P1C7C49 Hybrid/EV Battery Voltage System Isolation (A/C Area) Internal Electronic Failure P1C7D49 Hybrid/EV Battery Voltage System Isolation (Hybrid/EV Battery Area) Internal Electronic Failure P1C7E49 Hybrid/EV Battery Voltage System Isolation (Transaxle Area) Internal Electronic Failure P1C7F49 Hybrid/EV Battery Voltage System Isolation (Direct Current Area) Internal Electronic Failure P1C8049 Hybrid/EV Battery Voltage System Isolation (Rear Motor Area) Internal Electronic Failure
Table 2 Malfunction Content System Relevant DTC Microcomputer malfunction Motor generator control system P0A1A47 Generator Control Module Watchdog / Safety MC Failure P0A1A49 Generator Control Module Internal Electronic Failure P0A1B1F Generator Control Module Circuit Intermittent P0A1B47 Drive Motor "A" Control Module Watchdog / Safety MC Failure P0A1C47 Drive Motor "B" Control Module Watchdog / Safety MCU Failure P0A1C49 Drive Motor "B" Control Module Internal Electronic Failure P1C2A1C Generator A/D Converter Circuit Circuit Voltage Out of Range P1C2A49 Generator A/D Converter Circuit Internal Electronic Failure P1C2A71 Generator A/D Converter Circuit Actuator Stuck P1C2B1C Drive Motor "A" Control Module A/D Converter Circuit Voltage Out of Range P1C2B49 Drive Motor "A" Control Module A/D Converter Circuit Internal Electronic Failure P1C2B71 Drive Motor "A" Control Module A/D Converter Circuit Actuator Stuck P1C2C1C Drive Motor "B" Control Module AD Converter Circuit Voltage Out of Range P1C2C49 Drive Motor "B" Control Module AD Converter Internal Electronic Failure P1C2C71 Drive Motor "B" Control Module A/D Converter Circuit Actuator Stuck P310A83 Communication Error from Drive Motor "B" to Drive Motor "A" Value of Signal Protection Calculation Incorrect P310A86 Communication Error from Drive Motor "B" to Drive Motor "A" Signal (Some Circuit Quantity, Reported via Serial Data) Invalid P310A87 Communication Error from Drive Motor "B" to Drive Motor "A" Missing Message P310B83 Communication Error from Drive Motor "A" to Drive Motor "B" Value of Signal Protection Calculation Incorrect P310B86 Communication Error from Drive Motor "A" to Drive Motor "B" Signal (Some Circuit Quantity, Reported via Serial Data) Invalid P310B87 Communication Error from Drive Motor "A" to Drive Motor "B" Missing Message P313383 Communication Error from Generator to Drive Motor "A" Value of Signal Protection Calculation Incorrect P313386 Communication Error from Generator to Drive Motor "A" Signal Invalid P313387 Communication Error from Generator to Drive Motor "A" Missing Message P313483 Communication Error from Drive Motor "A" to Generator Value of Signal Protection Calculation Incorrect P313486 Communication Error from Drive Motor "A" to Generator Signal Invalid P313487 Communication Error from Drive Motor "A" to Generator Missing Message P32BF83 Lost Communication between Drive Motor "A" and "B" (Drive Motor "A") Value of Signal Protection Calculation Incorrect P32BF86 Lost Communication between Drive Motor "A" and "B" (Drive Motor "A") Signal (Some Circuit Quantity, Reported via Serial Data) Invalid P32BF87 Lost Communication between Drive Motor "A" and "B" (Drive Motor "A") Missing Message P32CF83 Lost Communication between Drive Motor "A" and "B" (Drive Motor "B") Value of Signal Protection Calculation Incorrect P32CF86 Lost Communication between Drive Motor "A" and "B" (Drive Motor "B") Signal (Some Circuit Quantity, Reported via Serial Data) Invalid P32CF87 Lost Communication between Drive Motor "A" and "B" (Drive Motor "B") Missing Message Hybrid control system P0A1B49 Drive Motor "A" Control Module Internal Electronic Failure Power source circuit malfunction Motor generator control system P06B01C Generator Control Module Position Sensor REF Power Source Circuit Voltage Out of Range P06B31C Drive Motor "B" Control Module Position Sensor REF Power Source Circuit Voltage Out of Range P06D61C Generator Control Module Offset Power Circuit Voltage Out of Range P19F81C Generator Control Module Offset Power Circuit Voltage Out of Range P19F91C Drive Motor "B" Control Module Offset Power Circuit Voltage Out of Range P26DF1C Generator Control Module Position Sensor REF Power Source Circuit Intermittent Communication malfunction Motor generator control system U11B387 Lost Communication with Hybrid/EV Powertrain Control Module (ch5) Missing Message Hybrid control system U117E87 Lost Communication with Drive Motor Control Module "A" (ch4) Missing Message Sensor and actuator circuit malfunction Motor generator control system P0A3F16 Drive Motor "A" Position Sensor Circuit Voltage Below Threshold P0A3F21 Drive Motor "A" Position Sensor Signal Amplitude < Minimum P0A3F22 Drive Motor "A" Position Sensor Signal Amplitude > Maximum P0A4516 Drive Motor "B" Position Sensor Circuit Voltage Below Threshold P0A4521 Drive Motor "B" Position Sensor Signal Amplitude < Minimum P0A4522 Drive Motor "B" Position Sensor Signal Amplitude > Maximum P0A4B16 Generator Position Sensor Circuit Voltage Below Threshold P0A4B21 Generator Position Sensor Signal Amplitude < Minimum P0A4B22 Generator Position Sensor Signal Amplitude > Maximum P0A6012 Drive Motor "A" Phase V Current (High Resolution) Circuit Short to Battery P0A6014 Drive Motor "A" Phase V Current (High Resolution) Circuit Short to Ground or Open P0A601C Drive Motor "A" Phase V Current (High Resolution) Circuit Voltage Out of Range P0A6312 Drive Motor "A" Phase W Current (High Resolution) Circuit Short to Battery P0A6314 Drive Motor "A" Phase W Current (High Resolution) Circuit Short to Ground or Open P0A631C Drive Motor "A" Phase W Current (High Resolution) Circuit Voltage Out of Range P0A6912 Drive Motor "B" Phase V Current(High Resolution) Circuit Short to Battery P0A6914 Drive Motor "B" Phase V Current(High Resolution) Circuit Short to Ground or Open P0A691C Drive Motor "B" Phase V Current(High Resolution) Circuit Voltage Out of Range P0A6C12 Drive Motor "B" Phase W Current(High Resolution) Circuit Short to Battery P0A6C14 Drive Motor "B" Phase W Current(High Resolution) Circuit Short to Ground or Open P0A6C1C Drive Motor "B" Phase W Current(High Resolution) Circuit Voltage Out of Range P0BE512 Drive Motor "A" Phase U Current Sensor Circuit Short to Battery P0BE514 Drive Motor "A" Phase U Current Sensor Circuit Short to Ground or Open P0BE528 Drive Motor "A" Phase U Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure P0BE912 Drive Motor "A" Phase V Current Sensor Circuit Short to Battery P0BE914 Drive Motor "A" Phase V Current Sensor Circuit Short to Ground or Open P0BE928 Drive Motor "A" Phase V Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure P0BED12 Drive Motor "A" Phase W Current Sensor Circuit Short to Battery P0BED14 Drive Motor "A" Phase W Current Sensor Circuit Short to Ground or Open P0BED28 Drive Motor "A" Phase W Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure P0BF112 Drive Motor "B" Phase U Current Sensor Circuit Short to Battery P0BF114 Drive Motor "B" Phase U Current Sensor Circuit Short to Ground or Open P0BF128 Drive Motor "B" Phase U Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure P0BF512 Drive Motor "B" Phase V Current Sensor Circuit Short to Battery P0BF514 Drive Motor "B" Phase V Current Sensor Circuit Short to Ground or Open P0BF528 Drive Motor "B" Phase V Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure P0BF912 Drive Motor "B" Phase W Current Sensor Circuit Short to Battery P0BF914 Drive Motor "B" Phase W Current Sensor Circuit Short to Ground or Open P0BF928 Drive Motor "B" Phase W Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure P0BFD62 Drive Motor "A" Phase U-V-W Current Sensor Signal Compare Failure P0BFE62 Drive Motor "B" Phase U-V-W Current Sensor Signal Compare Failure P0C5013 Drive Motor "A" Position Sensor Circuit "A" Circuit Open P0C5016 Drive Motor "A" Position Sensor Circuit "A" Circuit Voltage Below Threshold P0C5017 Drive Motor "A" Position Sensor Circuit "A" Circuit Voltage Above Threshold P0C5513 Drive Motor "B" Position Sensor Circuit "A" Circuit Open P0C5516 Drive Motor "B" Position Sensor Circuit "A" Circuit Voltage Below Threshold P0C5517 Drive Motor "B" Position Sensor Circuit "A" Circuit Voltage Above Threshold P0C5A13 Drive Motor "A" Position Sensor Circuit "B" Circuit Open P0C5A16 Drive Motor "A" Position Sensor Circuit "B" Circuit Voltage Below Threshold P0C5A17 Drive Motor "A" Position Sensor Circuit "B" Circuit Voltage Above Threshold P0C5F13 Drive Motor "B" Position Sensor Circuit "B" Circuit Open P0C5F16 Drive Motor "B" Position Sensor Circuit "B" Circuit Voltage Below Threshold P0C5F17 Drive Motor "B" Position Sensor Circuit "B" Circuit Voltage Above Threshold P0C6413 Generator Position Sensor Circuit "A" Circuit Open P0C6416 Generator Position Sensor Circuit "A" Circuit Voltage Below Threshold P0C6417 Generator Position Sensor Circuit "A" Circuit Voltage Above Threshold P0C6913 Generator Position Sensor Circuit "B" Circuit Open P0C6916 Generator Position Sensor Circuit "B" Circuit Voltage Below Threshold P0C6917 Generator Position Sensor Circuit "B" Circuit Voltage Above Threshold P0D2D16 Drive Motor "A" Inverter Voltage Sensor (VH) Circuit Voltage Below Threshold P0D2D17 Drive Motor "A" Inverter Voltage Sensor (VH) Circuit Voltage Above Threshold P0DFA62 Generator Phase U-V-W Current Sensor Signal Compare Failure P0E0012 Generator Phase U Current Sensor Circuit Short to Battery P0E0014 Generator Phase U Current Sensor Circuit Short to Ground or Open P0E0028 Generator Phase U Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure P0E0412 Generator Phase V Current Sensor Circuit Short to Battery P0E0414 Generator Phase V Current Sensor Circuit Short to Ground or Open P0E0428 Generator Phase V Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure P0E0812 Generator Phase W Current Sensor Circuit Short to Battery P0E0814 Generator Phase W Current Sensor Circuit Short to Ground or Open P0E0828 Generator Phase W Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure P0E3116 DC/DC Converter Voltage Sensor "A" (VL) Circuit Voltage Below Threshold P0E3117 DC/DC Converter Voltage Sensor "A" (VL) Circuit Voltage Above Threshold P0E5111 DC/DC Converter Current Sensor Circuit Short to Ground P0E5115 DC/DC Converter Current Sensor Circuit Short to Battery or Open P0E5128 DC/DC Converter Current Sensor Signal Bias Level Out of Range / Zero Adjustment Failure P0E512A DC/DC Converter Current Sensor Signal Stuck In Range P1CAC49 Generator Position Sensor Internal Electronic Failure P1CAD49 Drive Motor "A" Position Sensor Internal Electronic Failure P1CAE49 Drive Motor "B" Position Sensor Internal Electronic Failure P1CAF38 Generator Position Sensor REF Signal Cycle Malfunction Signal Frequency Incorrect P1CB038 Drive Motor "A" Position Sensor REF Signal Frequency Incorrect P1CB138 Drive Motor "B" Position Sensor REF Signal Frequency Incorrect P1CFF62 Hybrid/EV Battery Current/DC/DC Converter Current Signal Compare Failure Hybrid control system P0C7600 Hybrid/EV Battery System Discharge Time Too Long P0D2D1C Drive Motor "A" Inverter Voltage Sensor Voltage Out of Range P0E311C Boosting Converter Voltage Sensor "A" Voltage Out of Range P1C2D62 Hybrid/EV Battery "A" Voltage Sensor/Boosting Converter Voltage Sensor "A" Signal Compare Failure System malfunction Motor generator control system P0A9000 Drive Motor "A" Performance P0A9100 Drive Motor "B" Performance P0A9200 Hybrid/EV Generator Performance P0BFF1D Drive Motor "A" Circuit Current Out of Range P0C021D Drive Motor "B" System Circuit Current Out of Range P0C1900 Drive Motor "A" Execution Torque Performance P0C1A00 Drive Motor "B" Execution Torque Performance P0E7100 Generator Execution Torque Performance P1CA51D Hybrid/EV Generator Circuit Current Out of Range
PROCEDURE
- Result:
Result Proceed to OK A NG (The connector is not connected securely.) B NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C
A
B
C