ON BOARD CHARGER



The on board charger converts household single-phase AC power into DC power (300 V) to charge the drive battery.
Construction

The on board charger monitors input and output voltages, current and pilot signal. If detecting the abnormal conditions, the on board charger should stop a charge. The four temperature sensors are mounted at the inside of the on board charger to monitor the temperature of the inside circuits of the on board charger. When the temperature of the inside circuits of the on board charger becomes high, the cooling request signal should be sent to the PHEV-ECU to drive the electric motor unit cooling system. When the temperature abnormally becomes high, the charge should be stopped.
System configuration

When the charging cable is connected between the vehicle and the home plug with the electric motor switch turned OFF, the electrical power should be provided to the on board charger from the home plug. The on-board charger to which the power supply is provided sends the activation signal of charge to the PHEV-ECU. The PHEV-ECU turns ON the EV control relay with the charging activation signal. The voltage is applied to the PHEV-ECU power supply. The PHEV-ECU turns ON the IGCT control relay and activates the on board charger. The activated on board charger measures the input power supply voltage for home use, which is sent to the PHEV-ECU. The PHEV-ECU issues the on board charge voltage command and the on board charge current command to the on board charger and then, charging the drive battery starts. When knowing that the charge conditions of the drive battery are sent from the BMU through the CAN and detecting the fully charged conditions, the PHEV-ECU should stop the charge.

CHARGING INDICATOR LAMP



The charging indicator lamp is located in the combination meter and shows the drive battery charging status.
When detecting that the normal charge connector is connected with the normal charge port, the PHEV-ECU should make the charging lamp blink. When detecting that the charging starts, the PHEV-ECU should make the charging lamp illuminated. When detecting that the charging finishes, the PHEV-ECU should make the charging indicator lamp extinguished.

DIAGNOSIS SYSTEM


The on board charger has the following functions to easily check the system.

For each item, refer to the Workshop Manual.

CHARGING CABLE



The charging cable is mounted on the vehicle as an accessory of the vehicle. Connecting the cable between the vehicle and the home socket can make the drive battery charged. There is the switch in the normal charging plug of the charging cable. The switch is turned ON/OFF, depending on the normal charging plug release button status. When the normal charging plug is correctly connected with the vehicle, the switch should be ON and the signal should be input into the PHEV-ECU. When the normal charging plug release button is pressed from that status, the switch should be turned OFF and the signal should be input into the PHEV-ECU. This allows the PHEV-ECU to detect the insertion status of the normal charging plug.

The charging cable has the charging circuit interrupting device. When connecting the charging cable with home sockets, the AC power supply should be input into the charging circuit interrupting device. At that time, the POWER indicator (green lamp) of the charging circuit interrupting device should be lit. When connecting the charging cable with home sockets and the vehicle, the charging circuit interrupting device should send the pilot signal to the on board charger. This allows the on board charger to detect the supplied currents and charging should be enabled. When the drive battery starts to be charged, the CHARGING indicator (green lamp) of the charging circuit interrupting device should be lit. When the drive battery is finished to be charged, the CHARGING indicator (green lamp) should be blinking. When the manual stop button is pressed during the drive battery charging, the charging will terminate and the STOP indicator illuminates. When charging it again, pull the normal charging plug and insert it again.
The charging circuit interrupting device has the function detecting whether earth leakages exist or not; also the charging circuit interrupting device has the function detecting charging cable abnormalities. If detecting abnormalities, the charging circuit interrupting device should shut down the AC power supply and should light or blink the FAULT indicator (red lamp) of the charging circuit interrupting device.