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Hybrid03 High-Voltage Battery.pdf

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HYBRID03 HIGH VOLTAGE BATTERY
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TOYOTA Hybrid System - Course 071 3-1 Thesealednickel-metalhydride(Ni-MH)batterytechnologydeveloped forthehybridsystemprovidesbothhighpowerdensityandexcellent longevity.Thehybridsystemcontrolschargeanddischargeratesto keeptheHVbatteryataconstantStateofCharge(SOC). HV Battery Layout The HV Battery, Battery ECU and SMR (System Main Relay) are enclosed in a single case located in the luggage compartment behind the rear seat. Figure 3.1 T071f301c Section 3 High-Voltage Battery OverviewSection 3 3-2 TOYOTA Technical Training Thepowercableisahigh-voltage,high-amperagecablethatconnects theHVbatterywiththeinverterandtheinverterwithMG1andMG2. Inthe’04&laterPrius,thepowercablealsoconnectstheinverterwith theA/Ccompressor. Thepowercableisroutedundertherearseat,throughthefloorpanel, alongtheunder-the-floorreinforcement,andconnectstotheinverterin theenginecompartment.The12VDCwiringharnessfollowsasimilar routefromtheauxiliarybatterytothefrontofthevehicle Thepowercableisshieldedtoreduceelectromagneticinterference. Foridentificationpurposes,thehigh-voltagewiringharnessand connectorsarecolor-codedorangetodistinguishthemfromordinary low-voltagewiring. Power Routing Cable Figure 3.2 T071f302c Power CableHigh-Voltage Battery TOYOTA Hybrid System - Course 071 3-3 TheHVbatterypackcontainssixnickel-metalhydride1.2Vcellsthat areconnectedinseriestoformonemodule. Inthe’01-03Prius,38modulesaredividedintotwoholdersand connectedinseries.Thus,theHVbatterycontainsatotalof228cells andhasaratedvoltageof273.6V. Inthe’04andlaterPrius,28modulesareconnectedforaratedvoltage of201.6V.Thecellsareconnectedintwoplacestoreducetheinternal resistanceofthebattery. TheelectrodeplatesintheHVbatteryaremadeofporousnickeland metalhydridealloy. Forbatteryrecyclinginformation,pleaserefertotheWarrantyPolicy andProceduremanual. HV Battery Pack ’04 Prius and Later ’01-‘03 Prius Battery pack voltage 201.6V 273.6V Number of Ni-MH battery modules in the pack 28 38 Number of cells 168 228 Ni-MH battery module voltage 7.2V HV Battery Main Components (’04 & later Prius) Figure 3.3 T071f303c HV - Nickel-Metal Hydride Battery NOTE HV Battery Pack InformationSection 3 3-4 TOYOTA Technical Training ThebatteryECUprovidesthefollowingfunctions: w Itestimatesthecharging/dischargingamperageandoutputscharge anddischargerequeststotheHVECUsothattheSOCcanbe constantlymaintainedatacenterlevel. w Itestimatestheamountofheatgeneratedduringchargingand discharging,andadjuststhecoolingfantomaintainHVbattery temperature. w Itmonitorsthetemperatureandvoltageofthebatteryandifa malfunctionisdetected,canrestrictorstopchargingand dischargingtoprotecttheHVbattery. Battery ECU (’04 & later Prius) Figure 3.4 T071f304p Battery ECUHigh-Voltage Battery TOYOTA Hybrid System - Course 071 3-5 ThebatteryECUconstantlymonitorsHVbatterytemperature,voltage andamperage.ItalsochecksforleaksintheHVbattery. Whilethevehicleisinmotion,theHVbatteryundergoesrepetitive charge/dischargecyclesasitbecomesdischargedbyMG2during acceleration,andchargedbytheregenerativebrakeduring deceleration.TheBatteryECUestimatesthecharge/discharge amperageandoutputscharge/dischargerequeststotheHVECUto maintaintheSOCatamedianlevel. ThetargetSOCis60%.WhentheSOCdropsbelowthetargetrange, thebatteryECUinformstheHVECU.TheHVECUthensignalsthe engineECMtoincreasepowertochargetheHVbattery.IftheSOCis below20%,theengineisnotproducingpower. Thenormal,lowtohighSOCdeviationis20%.IftheDeltaSOC exceeds20%,thismeansthattheHVbatteryECUcannotcorrector maintaintheSOCdifferencewithintheacceptablerange. SOC The battery ECU outputs requests to the HV ECU so the SOC can be maintained at a center level. Figure 3.5 T071f305c State Of Charge (SOC) Delta SOCSection 3 3-6 TOYOTA Technical Training TheSystemMainRelay(SMR)connectsanddisconnectspowertothe high-voltagecircuitbasedoncommandsfromtheHVECU.Atotalof threerelays(oneforthenegativesideandtwoforthepositiveside)are providedtoensureproperoperation. Whenthecircuitisenergized,SMR1andSMR3areturnedON.The resistorinlinewithSMR1protectsthecircuitfromexcessiveinitial current(called‘inrush’current).Next,SMR2isturnedONandSMR1 isturnedOFF,allowingcurrenttoflowfreelyinthecircuit. Whende-energized,SMR2andSMR3areturnedOFFinthatorder andtheHVECUverifiesthattherespectiverelayshavebeenproperly turnedOFF. System Main Relay (SMR) The SMR connects and disconnects the power source of the high-voltage circuit. A total of three relays (one for the negative side and two for the positive side) are provided to ensure proper operation. Figure 3.6 T072f040c System Main Relay (SMR)High-Voltage Battery TOYOTA Hybrid System - Course 071 3-7 Whentheserviceplugisremovedthehigh-voltagecircuitisshutOFF attheintermediatepositionoftheHVbattery. Theserviceplugassemblycontainsasafetyinterlockreedswitch. Liftingtheclipontheserviceplugopensthereedswitch,shuttingOFF theSMR. Themainfuseforthehigh-voltagecircuitisinsidetheserviceplug assembly. Forsafetyreasons,youmustalwaysturnthevehicleOFFbefore removingtheserviceplug. ThebatteryECUdetectsbatterytemperatureviathreetemperature sensorsintheHVbatteryandoneintakeairtemperaturesensor. Basedonthosereadings,thebatteryECUadjuststhedutycycleofthe coolingfantomaintainthetemperatureoftheHVbatterywithinthe specifiedrange. ThebatteryECUkeepsthefanOFForrunningatLOif: w TheA/Cisbeingusedtocoolthevehicle. w Somemarginisleftinthetemperatureofthebattery. HV Battery Cooling System (’01-’03 Prius) Figure 3.9 T071f309p Service Plug NOTE HV Battery Cooling SystemSection 3 3-8 TOYOTA Technical Training HV Battery Cooling System (’04 & later Prius) Figure 3.10 T071f310c ThePriususesanAbsorbedGlassMat(AGM)12Vmaintenancefree auxiliarybattery.This12Vbatterypowersthevehicle’selectrical systemsimilartoaconventionalvehicle.Thebatteryisgroundedto themetalchassisofthevehicleandventedtoambient(outside)air withatube. Thisbatteryisverysensitivetohigh-voltage.Whenchargingthe auxiliarybatteryyoushouldusetheToyotaapprovedcharger,because astandardbatterychargerdoesnothavethepropervoltagecontrol andmaydamagethebattery.Iftheapprovedchargerisnotavailable youmayuseatricklechargeriftheamperageiskeptbelow3.5A. Thebatteryshouldberemovedfromthevehicleduringcharging. However,itissafetojump-startthePriusfromeitherthebatteryor thejump-startterminalunderthehood.Thiswillallowthevehicle’s chargingsystemtorestorethebatterytonormalSOC. Ifthevehiclewillnotbeusedformorethantwoweeks,disconnectthe 12Vbatterytopreventitfromdischarging.Alwaysmakesurethatall doorsareproperlyclosedandthattheinteriorlightsareOFF,especially overnight.Thesesituationswillquicklydepletethe12Vbattery. Auxiliary BatteryHigh-Voltage Battery TOYOTA Hybrid System - Course 071 3-9 Auxiliary Battery In glass mat batteries, the electrolyte is trapped in separators to reduce the amount of hydrogen gas released when the battery is charged. Glass mat batteries are sealed and the electrolyte cannot be replaced. Figure 3.11 T071f311c Auxiliary Battery Charging (’04 & later Prius) There is a remote access B + terminal in the main junction block under the hood, so it is no longer necessary to remove interior trim pieces to gain access to the battery. Figure 3.12 T071f312pSection 3 3-10 TOYOTA Technical TrainingHigh-Voltage Battery TOYOTA Hybrid System - Course 071 3-11 WORKSHEET 3-1 Hybrid Diagnostic Trouble Codes Vehicle Year/Prod. Date Engine Transmission Worksheet Objectives In this worksheet you will diagnose hybrid malfunctions by viewing DTCs, Information Codes, and the HV ECU Data List. Tools and Equipment w Vehicle w Diagnostic Tester w Printer w Repair Manual or TIS Section 1: Hybrid Diagnosis 1. When starting the vehicle (READY light ON) do any warning lights illuminate? If so, which ones? 2. Connect the Diagnostic Tester to DLC3. Select Codes All to check all the ECUs. 3. How many systems are checked when using Codes All? 4. List the systems that show NG (No Good). 5. Now view the Information Codes by pressing enter on the systems that say NG, then press enter again. Highlight the number next to INFORMATION and press enter.Section 3 3-12 TOYOTA Technical Training 6. Use the Repair Manual or TIS to look up the DTC and Information Code in order to find what part of the system is affected. List this information below. 7. Is there any information in the HV ECU Data List that can help you diagnose the vehicle? If so, print and highlight the information. 8. After diagnosing the vehicle, clear the codes and return to the classroom. Hint: To clear DTCs, you must exit out of CODES ALL and enter each section individually.High-Voltage Battery TOYOTA Hybrid System - Course 071 3-13 SELF-ASSESSMENT 3-1 Hybrid Diagnostic Codes Name: Date: Self-assessment Objectives Review this sheet as you are doing the Hybrid DTC Diagnosis worksheet. Check off either category after completing the worksheet and instructor presentation. Ask the instructor if you have questions. The Comments section is for you to write notes on where to find the information, questions, etc. I have questions I know I can Topic Comment Locate vehicle warning lights. View Codes All using the Diagnostic Tester. View the Information Codes. Use TIS & Repair Manual to research these codes. View the HV ECU Data List. Clear Codes. TOYOTA HYBRID SYSTEMSection 3 3-14 TOYOTA Technical Training
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