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Hybrid06 Body Electrical.pdf

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HYBRID06 BODY ELECTRICAL
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TOYOTA Hybrid System - Course 071 6-1 Thebodyelectricalsystemincludesspecialtechnologytoincreasefuel efficiencyandaccommodatethespecialrequirementsofahybrid powertrain.Forinstance,the2004&laterPriususesanelectric compressorsothatA/Coperationisnotdependentontheengine.It alsousesahumiditysensortomakecabindehumidificationmore efficient. Tomaintaincommunicationbetweenthevehicle’smanyelectronic controlcomponents,hybridvehiclesusethreetypesofmultiplex communication:CAN,BEANandAVC-LAN.AGatewayECUisused tolinkthethreecircuits. ThePriusA/Cunitprovides2-wayflowsoitcanrecirculatewarm internalairinthefootwellwhilesimultaneouslyintroducingfresh,dry externalairtotheupperpartofthecabin.Thisallowsittoeffectively heatthevehicleanddemistthewindshieldatthesametime. w The‘01-’03Priusairconditioningiscontrolledfromtheair conditioningcontrolpanel. w The’04&laterPriusairconditioningsystemcanbecontrolled eitherfromtheairconditioningscreenonthemultidisplayorfrom switchesonthesteeringpad. Thesystemincludesseveralcomponentstomeetthespecial requirementsofahybridvehicle. w The’04&laterPriusincludesanelectriccompressorthatis poweredbytheinverteranddoesnotdrawanypowerunlessitis neededtoruntheA/C. w ThehybridvehicleA/CsystemalsousestwoPositiveTemperature Coefficient(PTC)heatersembeddedintheheatercoreto supplementtheheatprovidedbytheengine. TheA/Ccontrolcircuitsincludespeciallogictailoredtosupportthe hybridpowertrain.IftheHVbatterybecomestoowarmwith recirculationON,theHVbatteryECUwillswitchtoFRESHinorder toincreasetheflowofairacrossthebattery. Section 6 Body Electrical Overview Air Conditioning SystemSection 6 6-2 TOYOTA Technical Training A/C Main Components (’04 later Prius) Figure 6.1 T071f601cBody Electrical TOYOTA Hybrid System - Course 071 6-3 Thehybridvehicle’sgasolineengineissmall,thermallyefficient,and runsonlywhenneeded.Therefore,enginecoolantmaynotalwaysbe hotenoughtoheatthecabintoacomfortabletemperature.Toaddress this,two165-WattPTCheaterelementsareembeddedintheheater coreandusedtosupplementengineheatwhenwarmingthevehicle. Heater Core Figure 6.2 T071f602 PTC Heater Figure 6.3 T071f603 Heater Core and PTC HeaterSection 6 6-4 TOYOTA Technical Training ThePriusA/Ccondenserincludesasub-coolerthatimprovesheat exchangeefficiency.Aftertherefrigerantpassesthroughthe condensingportionofthecondenser,boththeliquidrefrigerantand anygaseousrefrigerantthatwasnotliquefiedduringcondensationare cooledagaininthesuper-coolingportionofthecondenser.Becauseof thistwo-stepapproachtherefrigerantsenttotheevaporatorisalmost completelyliquefied. Whenrechargingmostcoolingsystems,airbubblesdisappearfromthe refrigerantwhenthesystemisfull.Withthissystem,however,air bubbleswilldisappearfromtherefrigerant beforethesystemisfull. SeethePriusRepairManualforthepropermethodofrechargingthis system. Sub-Cool Cycle Figure 6.4 T072f052c The’01-‘03Priususesascrollcompressorwithanoilseparatorthat reducesthecirculationofcompressoroilinthesystem. WhendiagnosingtheA/C,youmayneedtoforcetheA/Csystemto remainon.SettingthecontrolstotheMAXA/Cpositionwillcausethe enginetoremainon,maintainingA/Ccompressoroperation. Condenser and Sub-Cool Cycle NOTE Compressor (’01-‘03 Prius) NOTEBody Electrical TOYOTA Hybrid System - Course 071 6-5 A/C Compressor Selecting MAX A/C on the ’01-’03 Prius will cause the engine to run continuously Figure 6.5 T071f605p The’04&laterPriususesanelectriccompressordrivenbyan integratedmotor.Themotorrunson201.6VACsuppliedbytheA/C invertersocompressoroperationdoesnotdependontheengine. Theelectriccompressorconsistsofaspirallywoundfixedscrolland variablescroll,abrushlessmotor,andanoilseparator.Theoil separatorreclaimsmostofthecompressoroilthatisintermixedwith therefrigerant.Toinsureproperinsulationbetweenthecompressor housingandthehigh-voltagecomponentsinsidethecompressor,the ’04PriususesaspecialhighinsulationvalueND11compressoroil. NEVERuseanycompressoroilotherthanND11. TheA/Ccompressorispoweredby201.6VAC.Sowhenservicingthe A/Ccompressoryoushouldusethesamehighvoltagesafety proceduresyouwoulduseforthevehiclesotherhighvoltagecircuits. Electric A/C Compressor (’04 & later Prius) Figure 6.6 T071f606p Electric Compressor (’04 & later Prius) NOTESection 6 6-6 TOYOTA Technical Training Theroomtemperaturesensorincludesahumiditysensortohelpmake theA/Csystem’sdehumidificationprocessmoreeffective.Asaresult, compressorpowerconsumptionhasbeenreducedwhilestill maintainingacomfortablehumiditylevelwithinthecabin. Thehumidity-sensingresistancefilmcontainssmallcarbonparticles. Ashumidityinthecabinchangesthehydroscopicfilmexpandsand contracts,changingthedistancebetweenthecarbonparticles.This changestheresistanceofthefilmandsensoroutputvoltage. Humidity Sensor (’04 & later Prius) Figure 6.7 T071f607c Room Temperature Sensor and Humidity Sensor (’04 & later Prius)Body Electrical TOYOTA Hybrid System - Course 071 6-7 Theelectricwaterpumpprovidesstableheaterperformanceevenwhen theengineisstopped.Whentheengineisrunningtheengine’swater pumpisforcingcoolantthroughthesystemsotheelectricwaterpump doesnotoperate. Onthe’01-’03Prius,whentheengine’swaterpumpisoperatinga bypassvalveopenstominimizeflowresistance.Thebypassvalvehas beendiscontinuedonthe’04&laterPriusbecauseanewpumpdesign minimizeswaterflowresistance. Water Pump Coolant Flow (’01-‘03 Prius) Figure 6.8 T072f053c Water PumpSection 6 6-8 TOYOTA Technical Training ThePriususesthefollowingcommunicationsystemstocoordinate vehicleactivities: w TheControllerAreaNetwork(CAN)linksvehiclecontrolsystems thatrequirehigh-speedcommunication,suchastheECM,HV ECU,SkidControlECUandothers. w TheBodyElectronicsAreaNetwork(BEAN)connectsthebody controlsystems. w TheAudioVisualCommunicationLocalAreaNetwork (AVC-LAN)linkstheaudiovisualsystemECUsanddevices. TheGatewayECUcontainscommunicationcircuitsthatallowthe CAN,BEANandAVC-LANsystemstoconnectwitheachother. Multiplex Communication (’04 & later Prius) Figure 6.9 T071f609c Multiplex Communication SystemBody Electrical TOYOTA Hybrid System - Course 071 6-9 CAN System Diagram CAN communication speed is 500 k bps (’04 & later Prius) Figure 6.10 T071f610c Control Chassis Electrical System Control Body Electrical System Control Protocol CAN (ISO Standard) BEAN (TOYOTA Original) AVC-LAN (TOYOTA Original) Communication Speed 500 k bps (Max. 1 M bps) Max. 10 k bps Max. 17.8 k bps Communication Wire Twisted-pair Wire AV Single Wire Twisted-pair Wire Drive Type Differential Voltage Drive Single Wire Voltage Drive Differential Voltage Drive Data Length 1-8 Byte (Variable) 1-11 Byte (Variable) 0-32 Byte (Variable) Figure 6.11 T071f611 CAN, BEAN & AVC-LAN Chart (’04 & later Prius)Section 6 6-10 TOYOTA Technical Training TheSULEV2001-2003Priuswarrantyoffers: w Basic-3years/36,000miles w Powertrain(Engine,Transaxlewithmotors)-5years/ 60,000miles w HybridSystem(HVBattery,HVBatteryECU,HybridECU, InverterandConverter)8years/100,000miles TheAT-PZEV2004&laterPrius,thewarrantyoffers: w Basic-3years/36,000miles w Powertrain(Engine,Transaxlewithmotors)-5years/60,000 miles w HybridSystem8years/100,000miles w EmissionPerformance,EmissionDefects,andHybridBatteryPack 150,000miles WarrantyBody Electrical TOYOTA Hybrid System - Course 071 6-11 WORKSHEET 6-1 Electric Air Conditioning System Vehicle Year/Prod. Date Engine Transmission Worksheet Objectives This worksheet will familiarize you with the operation of the high voltage A/C compressor on the 2004 and later Prius using Active Tests and viewing the high and low pressures. You will also become familiar with the customize modes on the Diagnostic Tester, which allow A/C functions to be modified to suit customer needs. Tools and Equipment w Vehicle w Pressure Gauges w Diagnostic Tester w Repair Manual w New Car Features Section 1: A/C Compressor 1. Describe the A/C compressor. What drives the compressor? What type of compressor is it? 2. What type of compressor oil is used and why is it unique to this system? 3. List the safety precautions that should be followed when servicing the A/C System.Section 6 6-12 TOYOTA Technical Training Section 2: Refrigerant Pressure 1. Turn the A/C OFF and then turn the vehicle OFF. 2. Connect the pressure gauges to the high and low-pressure service ports. 3. Restart the vehicle, verifying it is in READY mode. 4. Connect the Diagnostic Tester to DLC3. 5. Select Active Test and COMPRS TARG SPD. Start at zero and note the refrigerant pressure. Increase the RPM to 4000 and note the pressure. Increase the RPM to 6000 and note the pressure. Compressor Speed: Low Side Pressure: High Side Pressure: Compressor Speed: Low Side Pressure: High Side Pressure: Compressor Speed: Low Side Pressure: High Side Pressure: Section 3: Humidity Sensor 1. What is the purpose of the humidity sensor? 2. Where is the humidity sensor located? 3. Is the humidity sensor located on the A/C Data List?Body Electrical TOYOTA Hybrid System - Course 071 6-13 Section 4: A/C Data List 1. Select the A/C Data List using the Diagnostic Tester. Under User Data select EVAPORATOR TEMP, ROOM TEMP, HUMIDITY SENSOR, COMPRESSOR SPEED, and COMPRESSOR TARGET SPEED. 2. What is the relationship of the room temperature to the evaporator temperature when the A/C is OFF and then with the A/C ON? 3. What happens to the humidity sensor reading when the A/C is turned ON? 4. What happens to the compressor target speed when the humidity sensor and evaporator temperature sensor values drop? Section 5: Customize Mode 1. The Customize Mode allows air conditioning functions to be modified to suit the customers needs. Modes are changed using the Diagnostic Tester. 2. With the Diagnostic Tester connected to DLC3, enter the Customize Mode located on the second screen after you turn the tester ON. 3. Select Individual Change. List at least three A/C climate control modes that can be customized. Note: Return all cars to the original state and return to the classroom.Section 6 6-14 TOYOTA Technical TrainingBody Electrical TOYOTA Hybrid System - Course 071 6-15 SELF-ASSESSMENT 6-1 Electric Air Conditioning System Name: Date: Self-assessment Objectives Review this sheet as you are doing the Electric Air Conditioning 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 Describe the electric A/C compressor. Describe the safety precautions of why ND11 oil must be used. List the safety precautions to be followed when servicing the A/C system. Access Active Test and select compressor speed. Locate the humidity sensor using TIS or the repair manual. View the A/C Data List. Locate and use Customize Mode for A/C. TOYOTA HYBRID SYSTEMSection 6 6-16 TOYOTA Technical Training
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