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Home >> Toyota >> 2014 >> Prius Two >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 68 (Plug-In Charge Control System (Diagnostics - Introduction) (Plug-In)) >> Plug-In Charge Control System >> System Description [10/2013 - ] >> System Description [10/2013 - ]
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System Description [10/2013 - ]

WARNING: This page is about a different variant/trim than selected.
  1. FUNCTION OF MAIN COMPONENTS 
    1. The main components of the plug-in charge control system have the following functions:
      Component Function
      Plugin Charge Control ECU Assembly
      • Controls the electric vehicle charger to perform plug-in charging, based on the signals from switches, charging current and charging voltage.
      • Illuminates the charging indicator during plug-in charging.
      Electrical Vehicle Charger Assembly Converts the AC power supplied from the external outlet to DC power, boosts it to the battery voltage and supplies it to the HV battery.
      Power Management Control ECU Turns on the SMR (System Main Relay) after receiving the plug-in charge enable signal from the plug-in charge control ECU assembly.
      HV Battery Assembly Stores the power supplied from the external outlet via plug-in charging.
      Hybrid Battery Junction Block Assembly Charging Relay Based on the signals sent from the plug-in charge control ECU assembly, connects or disconnects the HV battery and the electric vehicle charger.
      Charging Cable (Electric Vehicle Charger Cable Assembly) Charging Connector Connects to the charging inlet (electric vehicle charger cable) and supplies power from an external outlet to the vehicle.
      Charging Circuit Interrupting Device (CCID) Stops the power supplied from the external outlet if an electric leak is detected on the vehicle. When normal conditions are detected and the reset button is pressed, power supply is resumed.
      Charging Inlet (Electric Vehicle Charger Cable) Connects to the charging connector on the charging cable (electric vehicle charger cable assembly) and supplies the power from the external outlet to the vehicle.
      Charging Indicator Illuminates, flashes or turns off to inform the user of the plug-in charging state of the HV battery.
      Charging Port Lid Switch Transmits the open/close signal from the charging port lid (battery charger connector opening lid sub-assembly) to the plug-in charge control ECU assembly.
      Charging Inlet Light (Spot Light Assembly) Illuminates the charging inlet.
      Charging Timer Switch (Satellite Switch Set) Sets the plug-in charge timer start time and finish time.
      ECM
      • Performs control of the engine in accordance with the target engine speed and required engine motive force received from the power management control ECU.
      • Transmits various engine operating condition signals to the power management control ECU.
      Combination Meter Assembly Charging Timer Indicator Illuminates to indicate that the plug-in charge timer is set.
      EV Drive Mode Indicator Light Indicates that the vehicle is in EV mode.
      Multi-information Display
      • The charge timer schedule display shows the plug-in charge scheduled starting time and finishing time.
      • The plug-in effect display shows the amount of CO2 reduced due to the plug-in system.
      • The EV driving ratio display shows the ratio of distance driven in EV mode to HV mode.
      • The energy monitor indicates the plug-in charging state.
      • Displays messages according to system malfunction conditions.
      • Receives the signal regarding the amount of charged electricity from the plug-in charge control ECU assembly.
  2. SYSTEM CONTROL 
    1. Control List
      1. The plug-in charge control system consists of the controls listed below:
        Control Outline
        Charging Control The plug-in charge control ECU assembly controls charging to either normal charging (maximum power) or slow charging (lower power) according to the State Of Charge of the HV battery. Normal charging is performed first, then, when the HV battery State Of Charge is nearing the fully charged state, the ECU assembly switches to slow charging.
        AC Input Control The plug-in charge control ECU assembly detects the allowable current value via the CPLT signals and transmits the AC input current restriction value request signal (ILMT) to the electric vehicle charger.
        Auxiliary Control When charging, the auxiliary battery voltage is lowered to the limit of the control range (13.5 V) in order to reduce the current applied to the accessories and auxiliary battery.
        Charging Timer Function The electric vehicle charge is controlled to start supplying power from the external outlet at the start time set using the charging timer switch (satellite switch set) or to complete charging at the set finish time.
        Remote Air Conditioning Control
        • The plug-in charge control ECU assembly receives remote air conditioning signals from the power management control ECU. If the SOC is above a predetermined level, the plug-in charge control ECU assembly transmits an output power signal to the electric vehicle charger assembly based on the AC input voltage signals.
        • The electric vehicle charger assembly receives this signal and supplies power to the A/C inverter.
  3. OPERATING CONDITION 
    1. After turning the power switch off, the plug-in charge control ECU assembly transmits a charge start request signal to the Charging Circuit Interrupting Device (CCID) and electric vehicle charger assembly by connecting the electric vehicle charger cable assembly to the charge inlet.
    2. The plug-in charge control ECU assembly receives charge enable signals from CCID and the electric vehicle charger assembly and drives the electric vehicle charger assembly, charge relay, SMR, DC-DC converter and charges the HV battery pack with HV battery voltage that has been boosted by the electric vehicle charger assembly.
      Fig 1: Identifying Vehicle Charging Flow Chart
      GTY338074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. FUNCTION 
    1. Plugin Charge Control ECU Assembly
      1. The plug-in charge control ECU assembly controls the plug-in charge control system based on information sent from the electric vehicle charger assembly, such as charger operation condition, output current, output voltage and input voltage. The plug-in charge control ECU assembly also controls the charging timer function, which enables the plug-in charging operation start time or finish time to be set.
      2. When the power switch is turned off and the charging cable (electric vehicle charger cable assembly) is connected to the charging inlet (electric vehicle charger cable), the plug-in charge control ECU assembly transmits a charge start request signal to the Charging Circuit Interrupting Device (CCID) and electric vehicle charger assembly.
      3. After receiving a plug-in charging operation enable signal from the Charging Circuit Interrupting Device (CCID) and electric vehicle charger assembly, the plug-in charge control ECU assembly activates the electric vehicle charger assembly, charging relay, and SMR (system main relay). The electric vehicle charger assembly outputs power, charging the HV battery. At this time, the charging indicator displays the HV battery charging state.
        Fig 2: Identifying Vehicle Charging System Diagram
        GTY329495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. CONSTRUCTION 
    1. Electric Vehicle Charger Assembly
      1. The case of the electric vehicle charger assembly is made of aluminum. This in conjunction with cooling fins and cooling blowers ensures heat radiation performance.
        Fig 3: Identifying Electric Vehicle Charger Assembly
        GTY331180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Electric Vehicle Charger Assembly *2 Cooling Blower
      2. The electric vehicle charger assembly converts the AC power supplied from the external outlet to DC power, boosts it to the HV battery voltage and charges the HV battery.
        Fig 4: Identifying Electric Vehicle Charger Assembly Circuit Diagram
        GTY326375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. The plug-in charge control ECU assembly actuates and stops the electric vehicle charger assembly, and requests it to charge.
      4. The electric vehicle charger assembly changes the AC 120 V*1 or AC 208 to 240 V*2 input power from the external power source to DC power and boosts it to the HV battery voltage. It then outputs it at 1.2 kW*1 or 2 kW*2 respectively.

        *1: When charging via a home outlet using the charging cable (electric vehicle charger cable assembly).

        *2: When charging at a charging station.

      5. The electric vehicle charger assembly has self-protection functions, such as over voltage protection, over current protection and over heat protection, so it will stop automatically and regulate the power, if needed. It also sends information about operating conditions to the plug-in charge control ECU assembly.
      6. Using an air-cooling method which employs the built-in cooling fan, temperature increases due to the electric vehicle charger assembly operation will be reduced.
    2. Charging Cable (Electric Vehicle Charger Cable Assembly)
      1. The charging cable (electric vehicle charger cable assembly) consists of a charging connector, Charging Circuit Interrupting Device (CCID) and plug.
        Fig 5: Identifying Electric Vehicle Charger Cable Assembly
        GTY341574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Charging Inlet (Electric Vehicle Charger Cable) *2 Charging Connector
        *3 Charging Cable (Electric Vehicle Charger Cable Assembly) *4 Charging Circuit Interrupting Device (CCID)
        *5 AC Electrical Power - -
      2. When the charging connector is connected to the charging inlet (electric vehicle charger cable), it starts supplying electrical power from the external power source to the vehicle. The micro switch that detects the connecting condition of the charging connector and charging inlet (electric vehicle charger cable assembly) is built into it, and it transmits the connection condition to the plug-in charge control ECU assembly.
        WARNING:

        Keep the connecting portion of the charging connector clear of foreign matter. If any foreign matter is present, problems may result such as an increase in charging time.

        Fig 6: Identifying Charging Connector Circuit Diagram
        GTY328700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Charging Circuit Interrupting Device (CCID)
      1. The CCID monitors electrical leakage while the vehicle is being charged from an external power source. If leakage or other problems are found, the built-in relay will cut off the power supply.
      2. The power indicator turns on while being connected to a 120 V outlet, and the error warning indicator will turn on if problems, such as a malfunction in which the built-in relay is forced to turn off, are detected.
        Fig 7: Identifying Charging Circuit Interrupting Device (CCID)
        GTY325420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Power Indicator *2 Error Warning Indicator
        *3 Test Button *4 Reset Button
        CCID FUNCTIONS

        Item Function
        Leakage Detection and Power Cut-off Electrical leakage will be detected through charging, and the 2 built-in relays will cut off the power supply.
        Functionality Check The leakage detection and power cut-off function can be checked in advance of charging by operating the test button manually.
        Control Pilot Circuit (CPLT) Transmits information about the state of the CCID to the plug-in charge control ECU assembly.
        Self Protection A built-in protection circuit will be operated to protect from unexpected external factors such as lightning.
        RESUMING BUILT-IN RELAY

        Condition Resuming method
        The relay turns off due to malfunctions, such as improper connection of the hybrid system, electric vehicle charger assembly or charging cable (electric vehicle charger cable assembly). Reconnect the charging cable (electric vehicle charger cable assembly) to the external power source.
        The relay turns off due to a leakage detected in the high-voltage circuit. Repair the leakage, and then reconnect the system to the external power source, or operate the reset button.
    4. Charging Relay
      1. The charging relay is integrated in the hybrid vehicle junction block assembly.
      2. During plug-in charging, based on signals from the plug-in charge control ECU assembly, the charging relay opens or closes the circuit that supplies the power from the electric vehicle charger assembly to the HV battery.
        Fig 8: Identifying Hybrid Vehicle Junction Block Assembly & Charging Relays
        GTY332454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Hybrid Vehicle Junction Block Assembly *2 Charging Relay (CHRB)
        *3 Charging Relay (CHRG) - -
        Front - -
    5. Charging Indicator
      1. The plug-in charge control ECU assembly illuminates, flashes or turns off the charging indicator to inform the user of the battery charging state.
        Fig 9: Identifying Charging Indicator
        GTY331263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Charging Indicator - -
        CHARGING INDICATOR OPERATING CONDITIONS

        Operation Condition
        Illuminate
        • Plug-in charging from an external power source.
        • The remote climate control system for plug-in HV is operating.
        Flash The plug-in charge control ECU assembly has detected an abnormality. Charging is not conducted in this case.
        Off
        • Charging has completed normally.
        • The specified amount of time has elapsed after detecting an abnormality.
    6. Charging Timer Switch (Satellite Switch Set)
      1. The charging timer switch (satellite switch set) is a momentary type switch. By pressing this switch, the charging operation start time or finish time can be set. The set time is displayed on the multi-information display. The timer function can be reset.
  6. SYSTEM DIAGRAM 
    Fig 10: Identifying Vehicle Charging System Diagram
    GTY342395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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