- VL Voltage
- VH Voltage
| Last Modified: 05-13-2024 | 6.11:8.1.0 | Doc ID: RM100000001GCOR |
| Model Year Start: 2020 | Model: Corolla | Prod Date Range: [01/2019 - 09/2022] |
| Title: HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for NICKEL METAL HYDRIDE BATTERY): P0CA300; DC/DC Converter Step Up Voltage Performance; 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022] | ||
|
DTC |
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:
Internal inverter malfunction
- Inverter with converter assembly internal circuit malfunction
Inverter low-voltage circuit malfunction
- The connectors are not connected properly
DESCRIPTION
The boost converter boosts the 201.6 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 201.6 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 |
|---|---|---|---|---|---|
|
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) |
|
Comes on |
Master Warning: Comes on |
HINT:
With the vehicle stopped, apply the parking brake and turn the power switch 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.
Related Data List
|
DTC No. |
Data List |
|---|---|
|
P0CA300 |
|
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. The motor generator control 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.
Click here
![2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for NICKEL METAL HYDRIDE BATTERY): UTILITY](/t3Portal/stylegraphics/info.gif)
-
When clearing the permanent DTCs, refer to the "CLEAR PERMANENT DTC" procedure.
Click here
- 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 and wait for 2 minutes or more.
- Turn the power switch on (IG) and turn the Techstream on.
- With the power switch on (IG) and wait for 5 seconds or more. [*1]
- Turn the power switch on (READY) and wait for 5 seconds or more. [*2]
-
Depress the accelerator pedal of the vehicle with the engine stopped and the shift lever in P to start the engine. [*3]
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 power switch on (READY) after repairs have been performed.
HINT:
[*1] to [*3]: 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 or N/A, perform the normal judgment procedure again.
CAUTION / NOTICE / HINT
CAUTION:
-
Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.
- Inspecting the high-voltage system
- Disconnecting the low voltage connector of the inverter with converter assembly
- Disconnecting the low voltage connector of the HV battery
-
To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.
-
After removing the service plug grip from the HV battery, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
-
After removing 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.
Click here
HINT:
Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.
*a
Without waiting for 10 minutes
NOTICE:
After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.
Click here
PROCEDURE
|
1. |
CHECK DTC OUTPUT |
(a) Connect the Techstream to the DLC3.
(b) Turn the power switch on (IG).
(c) Enter the following menus: Powertrain / Hybrid Control and Motor Generator / Trouble Codes.
(d) Check for DTCs.
Powertrain > Hybrid Control > Trouble Codes
Powertrain > Motor Generator > Trouble Codes
|
Result |
Proceed to |
|---|---|
|
P0CA300 only is output, or DTCs except the ones in the table below are also output. |
A |
|
DTCs of hybrid control system in the tables below are output. |
B |
|
DTCs of motor generator control system in the tables below are output. |
C |
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 |
|
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 |
||
|
P1C2A1C |
Generator A/D Converter Circuit Circuit Voltage Out of Range |
||
|
P1C2A49 |
Generator A/D Converter Circuit Internal Electronic Failure |
||
|
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 |
||
|
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 |
||
|
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 |
|
P06D61C |
Generator Control Module Offset Power Circuit Voltage Out of Range |
||
|
Communication malfunction |
Motor generator control system |
P312487 |
Lost Communication between Drive Motor "A" and HV ECU Missing Message |
|
Hybrid control system |
P312387 |
Lost Communication with Drive Motor Control Module "A" from Hybrid/EV Control Module 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 |
||
|
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 |
||
|
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 |
||
|
P0BFD62 |
Drive Motor "A" 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 |
||
|
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 |
||
|
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 |
||
|
Sensor and actuator circuit malfunction |
Motor generator control system |
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 |
||
|
P0E511C |
DC/DC Converter Current Sensor Circuit Voltage Out of Range |
||
|
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 |
||
|
P1CAF38 |
Generator Position Sensor REF Signal Cycle Malfunction Signal Frequency Incorrect |
||
|
P1CB038 |
Drive Motor "A" Position Sensor REF Signal Frequency Incorrect |
||
|
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 |
|
P0A9200 |
Hybrid Generator Performance |
||
|
P0BFF1D |
Drive Motor "A" Circuit Current Out of Range |
||
|
P0C1900 |
Drive Motor "A" Execution Torque Performance |
||
|
P0E7100 |
Generator Execution Torque Performance |
||
|
P1CA51D |
Hybrid Generator Circuit Current Out of Range |
||
HINT:
-
P0CA300 may be output as a result of the malfunction indicated by the DTCs above.
- The chart above is listed in inspection order of priority.
- 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.)
(e) Turn the power switch off.
| B |
|
GO TO DTC CHART (HYBRID CONTROL SYSTEM)
|
| C |
|
|
|
2. |
CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR) |
Click here
|
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 |
|
REPLACE INVERTER WITH CONVERTER ASSEMBLY
|
| B |
|
CONNECT SECURELY |
| C |
|
REPAIR OR REPLACE HARNESS OR CONNECTOR |
|
|