MCU,LDC
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
2
Configuration
Location of HPCU
Inverter 1
High Vol.
Battery
LDC
E-Oil Pump
Inverter 2
HSG
A/T
HCU (Hybrid Control Unit)
Drive Motor
Two Inverters
Hydraulic
Brake System
HPCU = HCU + Two Inverters + LDC
※ HPCU: Hybrid Power Control Unit
LDC
Water cooling
heat sink
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
3
Specification
Category
Description
HCU
32 bit MICOM
• Controls driving power
distribution
Motor
Maximum 245A
(650V/400A power module)
• Controls motor torque
HSG
Maximum 125A
(650V/200A power module)
• Controls HSG torque
Inverter
LDC
Remarks
• Supplies 12V to vehicle
electric devices, modules
• Charge the auxiliary battery
Nominal 1.8kW, Outputs 13.9V
Installed location: engine room
Package
Total volume : about 9.2 liter
Total weight : 12.5 kg
※ MCU vs.
Inverter
HPCU
MCU
LDC
Inverter
(HSG)
Inverter
(Motor)
HCU
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
4
Main components of Inverter
Control board
Power module
Capacitor
Control signal
for power module
Max. 600V
Heat sink
Current sensor
Bus bar
500A (Motor)
300A (HSG)
Inverter
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
5
Converter vs. Inverter
It changes the characteristics of electricity.
Classification of converters
Category
Description
Input
Output
AC-DC converter
Rectifier or PWM converter
AC (commercial)
DC
DC-AC converter
Inverter
DC
Alternated V,F
DC-DC converter
DC converter or DC chopper
DC
DC (Vol. up or down)
AC-AC converter
AC voltage controller
AC
Alternated V,F
※ V: Voltage, F: Frequency
Function of inverter:
A device to change DC power source into ‘alternated voltage and frequency’.
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
6
Inverter functional block diagram
Inputs (C) : via CAN
Control mode, Torque
command, Speed
command
Inverter (MCU)
A
Aux.
Battery
Outputs : via CAN
A: Motor temperature,
DC voltage, Inverter
temperature
Protection /
Fault diagnosis
High voltage
Battery
B
+
B: Torque limit
-
D: Estimated torque
E: Actual motor speed
Power
module
C
Motor control
D
E
Current
sensing
Motor
Speed
detector
Resolver
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
7
Inverter I/O diagram
LDC 10A
Aux.
battery
MCU/GCU
(Inverter)
Signal
connector
Motor
LDC
Ignition
(IG1)
Hybrid
CAN
Motor
control
IGBT
Chassis
CAN
EWP
High voltage
battery
A/C
compressor
HSG
control
Signal
connector
HSG
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
8
MCU/GCU I/O specification
MCU connector configuration
(Inverter signal connector)
PIN
1
4
5
12
13
17
20
21
28
29
33
34
36
38
3
11
19
27
PIN-NAME
TM
M_REZS1
M_REZS2
M_REZS3
M_REZS4
TI
I_REZS1
I_REZS2
I_REZS3
I_REZS4
VB3
IGN
VB2
VB1
M_REZ+
M_REZI_REZ+
I_REZ-
FUNCTION
MOTOR TEMP SENSOR SIG
M_REZS1
M_REZS2
M_REZS3
M_REZS4
HSG TEMP SENSOR SIG
I_REZS1
I_REZS2
I_REZS3
I_REZS4
BATTERY POWER SUPPLY
KEY INPUT
BATTERY POWER SUPPLY
BATTERY POWER SUPPLY
M_REZ+
M_REZI_REZ+
I_REZ-
CONNECTION
MOTOR TEMP SENSOR
MOTOR RESOLVER SENSOR
MOTOR RESOLVER SENSOR
MOTOR RESOLVER SENSOR
MOTOR RESOLVER SENSOR
HSG TEMP SENSOR
HSG RESOLVER SENSOR
HSG RESOLVER SENSOR
HSG RESOLVER SENSOR
HSG RESOLVER SENSOR
12V BATTERY
12V BATTERY
12V BATTERY
12V BATTERY
MOTOR RESOLVER SENSOR
MOTOR RESOLVER SENSOR
HSG RESOLVER SENSOR
HSG RESOLVER SENSOR
LEVEL
0~5V
0~5V
0~5V
0~5V
0~5V
0~5V
0~5V
0~5V
0~5V
0~5V
0~18V
0~18V
0~18V
0~18V
0~14V
0~14V
1~7V
1~7V
Remarks
Input signals
(Analog)
Output signals
(Analog)
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
9
Typical problems of inverter
Items
Sub-items
Probable causes
• connection fault of signal connector
1) CAN
• non-defined CAN ID used
Communication • error frame because of the fault in
communication line
Function
Performance
Phenomenon
• torque control impossible
- engine start impossible
- EV mode impossible
2) High DC
voltage
measurement
• connection fault of high voltage DC
connector
• high voltage battery relay fault
• pre-charge impossible
• torque control unstable
3) Rotor position
measurement
• connection fault of signal connector
• offset calibration not carried out for
resolver initial position
• signal line fault
• torque control unstable
4) Motor
temperature
measurement
• connection fault of signal connector
• output power of inverter
limited
• output power of inverter limited
• inverter over temperature
• Motor/ HSG over
temperature
5) Output
performance
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
10
Definition of LDC function
 Function of converter :
- A device to convert the particular level
of voltage into other level
 A sample of converting :
DC 100V
DC 5A
500W
DC 50V
DC 10A
500W
Switch “A”
DC 13.8V
DC 130A
1.8KW
DC 280V
DC 6.5A
1.8KW
[ case of TF HEV ]
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
11
Role of LDC
Conventional vehicle
TF Optima HEV
Engine
12V
Battery
Motor
Engine
12V
Battery
ALT
Alternator
Input
Output
Function
Energy flow
Characteristic
Inverter
Main battery
LDC
LDC (Low voltage DC-DC Converter)
Engine (mechanical connection)
Main battery (electrical connection)
12V battery/12V load
←
12V battery charge/12V load supply
←
Engine  ALT.  12V load
Engine  Drive motor/Inverter  Main battery  LDC 
12V load
- Idle stop: impossible to supply 12V
- Temperature: output degraded with
ambient temperature rise
- Auto stop: possible to supply 12V
- Temperature: constant power output
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
12
Current converting flow in LDC
B(+)
Vo(+)
Aux. battery
High
voltage
battery
Vo(-)
B(-)
Filter (input)
MOSFET
Transformer
Diode
(rectifier)
DC
AC
AC
AC
Filter (output)
Output
DC
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
13
Main components of LDC
Control/Sensing
circuit
Heat Sink
Noise Filter
Output Diode
Controller
control signal
Converter
Snubber / Capacitor
Transformer/
Inductor
Power module
(MOSFET)
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
14
LDC I/O diagram
LDC 10A
LDC
Aux.
battery
Chassis
CAN
LDC power
output
LDC signal
connector
Ignition
(IG1)
MOSFET
High voltage
battery
HPCU ass’y
HCU signal
connector
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
15
Variable voltage control
Strategy
Stop
LDC output
voltage
Aux.
Battery
status
Charging
Acceleration
Discharging
Cruising
Charging
Discharging
Deceleration
Auto stop
Charging
Discharging
Engine running
High
Mid.
Low
Data flow
 Temperature correction
 Voltage control command
CAN
Aux. battery
temperature sensor
BMS
CAN
HCU
LDC
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
16
Typical problems in LDC
items
Sub-items
Probable causes
Phenomenon
• connection fault of signal connector
1) CAN
• non-defined CAN ID used
communication • error frame because of fault in
communication line
• variable voltage control is
impossible
• cannot charge aux. battery
2) High DC
voltage
measurement
• connection fault of high voltage DC
connector
• pre-charge impossible
• LDC output voltage is
unstable
3) Output
performance
• output power limited
• LDC over temperature
• LDC over-load
Function
Performance
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
17
HPCU cooling system
+
Engine
coolant
reservoir
Engine
coolant
reservoir
Added
reservoir
Reservoir
Electric water
pump
Inlet hose
Inlet hose
Outlet hose
Outlet hose
To radiator
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
18
Electric Water Pump
Chassis CAN
EWP
Inverter
(MCU)
Stator Assembly
Rotor Assembly
Driver Cover
EWP
HSG
Impeller
Pin
Body Pump
Cover Pump
Description
1
CAN - Low
2
CAN - High
3
Ground
4
B+
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
19
EWP operation
Mode
Sequence
Condition
ON
Normal
mode
HPCU temp.
OFF
Coolant temp.
EWP
MCU
EWP
failure
mode
1
EWP
0
MCU
Cluster
Coolant
add mode
EWP
GDS
EWP ON :
HPCU temp. 45℃ ↑ OR Coolant temp. 35℃ ↑
EWP OFF :
HPCU temp. 40℃ ↓ AND Coolant temp. 30℃ ↓
1: No failure, 0: Failure
When EWP is failed, Service lamp in the cluster
is turned on by MCU and DTC is stored in MCU.
Need to drive EWP by GDS when you add coolant
MCU
ON
IG key status
OFF
EWP enable (‘1’)
CAN command signal
(MCU  EWP)
EWP disable (‘0’)
3,300 rpm
0 rpm
EWP motor speed
▽t ≤ 5 sec
EWP status signal via CAN
(EWP  MCU)
Normal mode
EWP failure mode
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
20
Air bleeding of HPCU cooling line
① Add coolant
④ Coolant level
High
② Connect GDS
⑤ Air bleeding (3min.)
③ Move to the menu of
Vehicle S/W :
Engine stop, IG ON
No DTC (P0C73)
⑥ Stop EWP, add coolant more
Full
Low
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
Air bleeding of HPCU cooling line
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
21
MCU,LDC
Current Data - MCU
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
22
MCU,LDC
23
MCU / GCU (Inverter) service data
Item
MCU
Item
Description
Unit
Phenomenon
Main relay cutoff
request flag by
MCU
The status of high voltage main relay cut
off request status
ON/OFF
ON: main relay off condition, EV/HEV mode
is impossible, failsafe driving by engine
running
Capacitor voltage
200~310V (main relay ON)
Lower than 180V (fault)
Higher than 380V (fault)
V
EV mode impossible and engine cannot be
started by neither motor nor HSG.
Motor controllable
flag
ON: inverter, motor is controllable
OFF: motor stops
ON/OFF
EV mode prohibited.
Engine can be started by HSG/GCU as long
as high voltage power is connected.
MCU ready flag
ON: MCU is ready to operate
OFF: MCU is not ready to operate
ON/OFF
EV mode prohibited, engine can be started
by HSG/GCU under ‘OFF’ condition .
MCU service lamp
ON request flag
ON: fault in MCU or motor
OFF: MCU & motor is OK
ON/OFF
MCU MIL on
request flag
ON: requests MIL on to ECU
OFF: does not request MIL
ON/OFF
EV mode prohibited (except temp. sensor
open/short circuit : power limited), engine can
be started by HSG/GCU
Motor actuation test
flag
ON: motor actuation test is operating
ON/OFF
-
MCU warning flag
ON: motor torque is limited
OFF: MCU or motor is OK
ON/OFF
EV mode is possible but motor torque is
limited, engine starts by HSG/GCU
MCU fault flag
ON: MCU and motor stops
OFF: MCU & motor is OK
ON/OFF
EV mode is impossible (as long as ‘ON’),
engine starts by HSG/GCU
MCU temperature
Normal range: -30~150℃
Inverter temp. sensor fail: 214℃
℃
EV mode is limited or impossible if MCU is
overheat but engine can be started by HSG.
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
24
MCU / GCU (Inverter) service data
Item
Item
Other
Aux. battery
voltage
9~16V (MCU normal operation)
< 9V or > 16V (MCU control stops)
< 6.5V or > 20V (CAN stops)
Actual motor
speed
Normal: 0~6,500 rpm
Same as engine speed as long as engine
clutch is engaged
32,768 rpm: motor position sensor failure
Motor torque
reference
Motor
GCU
Description
Unit
V
rpm
Phenomenon
If aux. battery voltage < 9V or > 16V,
Neither EV mode nor engine starting is
prohibited
If resolver is failed, EV mode is impossible and
engine can be started by HSG.
-
%
Actual motor
torque
It reduces as the motor speed increases.
(e.g. 1,200rpm or less 205Nm, 3,000rpm
95.5Nm)
Normal range: -100 ~ 99.8%
When this value is zero:
EV mode is impossible but engine can be started
by HSG.
Motor phase
current
When motor control stops, it shows zero
except high speed.
A
-
Motor temperature
Normal range: -20~200℃
Temp. sensor fail: 214℃
℃
GCU ready flag
ON: GCU is ready to operate
OFF: GCU is not ready to operate
ON/OFF
EV mode prohibited. Engine can be started by
MCU.
GCU service lamp
ON request flag
ON: fault in GCU or HSG
OFF: GCU & HSG is OK
ON/OFF
EV mode prohibited (except temp. sensor
open/short circuit : power limited), engine can be
started by MCU.
GCU warning flag
ON: Power is limited
OFF: GCU or HSG is OK
ON/OFF
Even if this value is ON, EV mode is possible by
MCU (power limited) and engine can be started
by MCU
EV mode is limited or impossible if motor is
overheat but engine can be started by HSG.
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
25
MCU / GCU (Inverter) service data
Item
GCU
HSG
Item
Description
GCU fault flag
ON: GCU and HSG stops
OFF: GCU & HSG is OK
GCU
temperature
Normal range: -30~150℃
GCU temp. sensor fail: 212℃
Actual HSG
speed
Normal: 0~16,500 rpm
32,768 rpm: HSG position sensor failure
HSG torque
reference
Unit
Phenomenon
ON/OFF
ON: EV mode prohibited. Engine can be started
by MCU.
℃
Even if GCU is overheat, EV mode is possible by
motor and engine can be started by motor and
engine clutch ‘compulsory lock-up’ engagement.
rpm
Even if HSG position sensor (resolver) is failed,
EV mode is possible by motor and engine can be
started by motor and engine clutch ‘compulsory
lock-up’ engagement.
It reduces as the HSG speed increases. (e.g.
1,200rpm or less 43.2Nm, 3,000rpm 26Nm)
Normal range: -100 ~ 99.8%
%
-
Actual HSG
torque
Normal range: -100 ~ 99.8%
Max. torque may reduce as the speed
increases.
%
Even if HSG torque is zero, EV mode is possible
by motor and engine can be started by motor and
engine clutch ‘compulsory lock-up’ engagement.
HSG phase
current
When HSG control stops, it shows zero
except high speed.
A
-
HSG
temperature
Normal range: -20~200℃
Temp. sensor fail: 212℃
℃
Even if HSG is overheat, EV mode is possible
and engine can be started by motor and engine
clutch ‘compulsory lock-up’ engagement.
HSG
controllable flag
ON: GCU and HSG can be controlled
normally.
OFF: HSG cannot be controlled.
ON/OFF
In case of ‘OFF’, EV mode is prohibited and
engine can be started by motor as long as the
high voltage is connected.
HSG actuation
test flag
ON: HSG motor actuation test is operating
ON/OFF
-
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
26
MCU / GCU (Inverter) service data
Item
Resolver
Item
Description
Unit
Phenomenon
rad
Resolver offset calibration may not
be possible if out of tolerance range.
HSG resolver
offset
Installing tolerance of resolver in HSG motor
Spec: 2.28rad, Tolerance: ±11rad
HSG resolver
CAL command
‘0’: calibration completed, ‘1’: calibration failure
‘2’: calibrating, ‘3’: calibration started
‘4’: No calibration was performed
-
In case of ‘4’, HSG may not operate.
HSG resolver Mal.
counter
Malfunction counter for HSG resolver.
HSG resolver failure will be set if it exceeds 132.
-
Probable cause: resolver failure,
poor wiring or connector, shock or
noise
Motor resolver
offset
Installing tolerance of resolver in traction motor
Spec: 2.28rad, Tolerance: ±11rad
rad
Resolver offset calibration may not
be possible if out of tolerance range.
Motor resolver
CAL command
‘0’: calibration completed, ‘1’: calibration failure
‘2’: calibrating, ‘3’: calibration started
‘4’: No calibration was performed
-
In case of ‘4’, HSG may not operate.
Motor resolver
Mal. counter
Malfunction counter for motor resolver.
HSG resolver failure will be set if it exceeds 132.
-
Probable cause: resolver failure,
poor wiring or connector, shock or
noise
Main relay cutoff
request flag by
GCU
The status of high voltage main relay cut off
request status
ON/OFF
ON: main relay off condition, EV/HEV
mode is impossible, failsafe driving
by engine running
ON/OFF
EV mode prohibited (except temp.
sensor open/short circuit : power
limited), engine can be started by
motor
GCU
GCU MIL on
request flag
ON: requests MIL on to ECU
OFF: does not request MIL
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
Current Data - LDC
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
27
MCU,LDC
28
LDC service data
Item
Description
Unit
LDC fault flag
ON: LDC stop to operate OR output is limited.
OFF: LDC is OK
ON/OFF
LDC service lamp
request flag
ON: LDC fail and operation may stop.
OFF: LDC is OK
ON/OFF
LDC ready status flag
ON: LDC is OK, check this value is ‘ON’ if LDC is OK.
OFF: LDC is abnormal, check aux. battery and LDC
ON/OFF
LDC operating status
ON: LDC outputs PWM normally
OFF: PWM output stops
ON/OFF
LDC Under Voltage
Control status
ON: LDC outputs low voltage (12.8V)
OFF: LDC outputs normally
ON/OFF
LDC power Derating
status
ON: Power is limited by LDC internal failures
- Temperature sensor failure OR Temperature > 78℃
- Input voltage is 180~200V
- LDC output current is higher than 135A OR
OFF: LDC is OK
LDC output voltage
Normal range: 12.8~14.1V
LDC control may stop if output voltage is lower than 9.0V or higher
than 18V
V
LDC output current
Nominal value is 130A, Max current is 135A by over current
protection function.
A
LDC input voltage
Normal range: 200~310V
180~200V: output power is limited
V < 180V or V > 345V : LDC control may stop.
V
LDC temperature
Temp sensor failure: 127℃
T > 78℃: power limit, T > 105℃: LDC stops
℃
ON/OFF
Phenomenon
Both EV mode and
engine starting are
possible
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
29
DTC (MCU / GCU)
System
DTC
MCU
power
module
(IGBT)
P0A78
Power
cable
P1C64
P0A51
Motor
Current
sensor
Inverter
Temp.
sensor
Motor
Temp.
sensor
Monitor strategy description
Threshold
Too high current in IGBT switch
Current > 2,800A
Power supply voltage of power module
is too low
Voltage < 9V
Open circuit in IGBT
Time
MIL
7 times within 10s.
immediately
Half-sine wave
0.5s
Motor power cable open circuit
Cable current < 10A
20ms
Short or open circuit in A/C current
sensor
Output>4.65V or <0.35V
5ms
2DC
2DC
2DC
P0A52
Rationality check
T.B.D
P0AF0
Open circuit or short to high voltage
P0AEE
Rationality check
P0AEF
Short to ground
V < 0.5
100ms
P0A2D
Open circuit or short to high voltage
V > 4.83
1s
P0A2C
Short to ground
V < 0.15
1s
P0A2B
Rationality check
V > 4.85, T > 30℃
T.B.D
T.B.D
T.B.D
100ms
T.B.D
2DC
2DC
T.B.D
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
30
DTC (MCU / GCU)
Compo
nent
Motor
rotor
position
sensor
Motor
Overheat
Motor
Over
current
HSG
power
module
DTC
Malfunction criteria
V > 4.25 or < 0.75
Time
P0A3F
Open or short circuit
P0A40
Rationality check
P0C17
Rotor position sensor calibration
Calibration flag
P0A3C
Inverter overheat check
T > 102℃
1s
P0A2F
Motor overheat check
T > 185℃
10s
P0A78
Over current checking
Current > 450A
3 times within 10s
Too high current in IGBT switch
Current > 2,800A
7 times within 10s.
Power supply voltage of power module
is too low
Voltage < 9V
MIL
660ms
2DC
P0A7A
Open circuit in IGBT
HSG
power
cable
Threshold
P1C6A
HSG power cable open circuit
T.B.D
Half-sine wave
Cable current < 10A
T.B.D
immediately
immediately
-
2DC
2DC
0.5s
20ms
2DC
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
31
DTC (MCU / GCU)
Compo
nent
HSG
Current
sensor
GCU
Temp.
sensor
HSG
Temp.
sensor
HSG
rotor
position
sensor
DTC
Malfunction criteria
P0A59
Short or open circuit in A/C current
sensor
Threshold
Output > 4.65V or < 0.35V
Time
MIL
5ms
2DC
P0A5A
Rationality check
T.B.D
P0BCF
Open circuit or short to high voltage
P0BCD
Rationality check
P0BCE
Short to ground
V < 0.5
P0A39
Open circuit or short to high voltage
V > 4.83, T > 30℃
1s
P0A38
Short to ground
V < 0.15
1s
P0A37
Rationality check
P0A4B
Open or short circuit
V > 4.85
T.B.D
100ms
T.B.D
T.B.D
2DC
100ms
T.B.D
V > 4.25 or < 0.75
2DC
T.B.D
660ms
2DC
P0A4C
Rationality check
P1C76
Rotor position sensor calibration
T.B.D
Calibration flag
T.B.D
immediately
-
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
32
DTC (MCU / GCU)
Component
DTC
HSG Overheat
P0A3E
Inverter overheat check
T > 102℃
1s
P0A3B
HSG overheat check
T > 185℃
10s
P0A7A
Over current checking
Current > 250A
U0001
C-CAN bus off check
T > 1s
-
U1001
H-CAN bus off check
T > 1s
-
U0293
HCU message missing (C-CAN)
T > 0.5s
-
HSG Over
current
Malfunction criteria
Threshold
Time
MIL
2DC
3 times within 10s
2DC
CAN
U1004
HCU message missing (H-CAN)
T > 0.5s
-
U0111
BMS message missing (C-CAN)
T > 2s
-
U1006
BMS message missing (H-CAN)
T > 2s
-
U1116
EWP message missing (C-CAN)
T > 2s
-
-
EWP
P0C73
EWP performance
EWP status = SET
Immediately
-
High voltage
interlock
P0A0D
Open connector of high voltage
cable
Interlock V > 3.5
0.3s
2DC
CPU
P0A1B
CPU communication failure
Goes to ‘disable’ mode
immediately
-
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
33
DTC (LDC)
Compo
nent
DTC
P0A94
Input
terminal
LDC output terminal is shorted
Failsafe
MIL
IG Off & On
LDC operation stops
-
IG Off & On
LDC output is limited
-
T < 73℃
LDC operation stops
-
To be determined
-
T.B.D
-
LDC input terminal open circuit
P0C3A
Sensing voltage is high than 4.7V
P0C3B
Sensing voltage is lower than 0.3V
Over
heat
P1A88
Temperature in diode is higher than
105℃
Current
sensor
P1A89
Sensing voltage < 1.5V
U0001
CAN Bus off for 1sec
U0293
HCU CAN signal missing for 2sec
Temp.
sensor
Release
condition
Vt – Vo > 1V for 10sec
(Abnormal LDC voltage control)
Voltage
control
Output
terminal
Malfunction criteria
CAN
U0111
BMS CAN signal missing for 2sec
U0110
MCU CAN signal missing for 2sec
IG Off & On
As soon as the
communication
restarts.
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
MCU,LDC
Actuation test - MCU
Copyright ⓒ 2010 All rights reserved. No part of this material may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the written permission of Kia Motors Corporation.
34