MOTOR GENERATOR CONTROL SYSTEM, Diagnostic DTC:P0CA300

DTC Code DTC Name
P0CA300 DC/DC Converter Step Up Voltage Performance

DTC SUMMARY


  1. 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 351.5 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 351.5 V in order to charge the HV battery.

B006HMUE13

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)

  • Wire harness or connector

  • Inverter with converter assembly

 Comes on

Master Warning Light:

Comes on

Tech Tips

With the vehicle stopped, apply the parking brake and turn the power switch on (READY).

With park (P) selected, 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

  • VL Voltage

  • VH Voltage

CONFIRMATION DRIVING PATTERN

Tech Tips

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


  1. Connect the GTS to the DLC3.

  2. Turn the power switch on (IG) and turn the GTS on.

  3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).

  4. Turn the power switch off and wait for 2 minutes or more.

  5. Turn the power switch on (IG) and turn the GTS on.

  6. Turn the power switch on (READY) and wait for 5 seconds or more.

  7. Press the HV/EV mode switch to enter HV drive mode.

  8. Depress the accelerator pedal of the vehicle with the engine stopped and park (P) selected to start the engine.

    Note

    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.

  9. Enter the following menus: Powertrain / Motor Generator / Utility / All Readiness.

  10. Check the DTC judgment result.

    Tech Tips


    • 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 driving pattern again.

CAUTION / NOTICE / HINT

CAUTION:


  • B006HUP

  • 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

    • Disconnecting the low voltage connector of the electric vehicle charger assembly

    • Disconnecting the low voltage connector of the solar energy control unit

  • B006IQP

    To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.

  • B006HQC

    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.

  • B006IVPC05
    *a Without waiting for 10 minutes

    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

    Tech Tips

    Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly and the electric vehicle charger assembly.

Note

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


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control and Motor Generator / Trouble Codes.

    4. Check for DTCs.


      Powertrain > Hybrid Control > Trouble Codes
      Powertrain > Motor Generator > Trouble Codes
      Result
      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 μC 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
      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
      P1CFF62 Hybrid/EV Battery Current/DC/DC Converter Current Signal Compare Failure
      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 after Boosting Voltage Sensor Circuit Voltage Out of Range
      P0E311C Drive Motor "A" Inverter before Boosting Voltage Sensor Circuit Voltage Out of Range
      P1C2D62 Drive Motor "A" Inverter before Boosting Voltage Sensor 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

      Tech Tips


      • P0CA300 may be output as a result of the malfunction indicated by the DTCs above.


        1. The chart above is listed in inspection order of priority.

        2. 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.)

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    C

    GO TO DTC CHART (MOTOR GENERATOR CONTROL SYSTEM) Click here

    A

  2. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)

    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

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. B006IZQ

      Check the connection condition of the low voltage connectors of the inverter with converter assembly and the contact pressure of each terminal. Check the terminals for deformation, and the connector for water and foreign matter.

      Click here

      Note

      Before disconnecting the connector, confirm that it is properly connected by checking that the claws of the lock levers are engaged and that the connector cannot be pulled off.

      OK
      - The connector is connected securely.
      - The terminals are not deformed and are connected securely.
      - No water or foreign matter in the connector.
      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

      Tech Tips

      When connecting the connector, connect it with the lock levers raised. Rotate each lock lever downward and make sure that the connector is securely connected. When a lock lever is fully lowered, a click will be heard as its claw engages. After the click is heard, pull up on the connector to confirm that it is securely connected.


    A

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

    B

    CONNECT SECURELY

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR