CHARGING SYSTEM [(E)]

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Outline

•  The charging system supplies power from household outlets and charging facilities to the vehicle to charge the high voltage battery.
•  There are 2 methods of charging including normal charging and quick charging.

Normal charging

•  Normal charging is the charging performed on a daily basis using a normal charging device at a charging facility or household.
•  With normal charging, alternating current is supplied from the charging equipment to the vehicle.
•  When alternating current from the charging equipment is supplied to the vehicle, alternating current is input to the battery charge control module.
•  The AC/DC converter in the battery charge control module converts alternating current to direct current to charge the high voltage battery.
•  Normal charging is possible when all the following conditions are met.
―  Parking lock is operated and shift lever is in P position.
―  SOC value is less than 100%
―  High voltage-related DTC is not output
―  Self-test of another function is not executed
―  Normal charge connector and quick charge connector are not connected at same time
―  Approx. 8 s (insulation check completed) have elapsed after inserting charge connector
•  The charging time is approx. 5 to 8 h (when charging facility is used) and approx. 8 to 13 h (when household outlet is used)
Note
•  The time required to charge the high voltage battery differs depending on the ambient temperature, high voltage battery temperature, state of charge, and years of use. In particular, charging takes longer under conditions in which the high voltage battery temperature and the ambient temperature are low.
•  The following functions can be used with the normal charging.
Charging timer function
―  The charging start and stop time can be set using the center display or a Smartphone.
Note
•  When the charging timer is set, the charging will not start until the timer set time has elapsed.
If immediate charging is required, cancel the charging timer.
Remote charging function
―  Charging can be started from a remote location using a Smartphone.
Full-charge priority function
―  When the charging timer start and finish time are set, and if the battery cannot be fully charged within the set time, the charging start time is advanced to resume charging.
Additionally, if the battery is not fully charged at the finish time, it continues charging until it is fully charged.


Quick charging

Caution
•  When operating the rapid charger, always follow the user instructions indicated on the rapid charger main unit. Otherwise, mistaken operation may damage the rapid charger and the vehicle.
•  Quick charging is the charging method using a quick charging equipment that can perform charging in a short period of time.
•  Charging can be done rapidly because quick charging is performed at a higher voltage compared to normal charging.
•  With quick charging, direct current is supplied from the charging equipment to the vehicle.
•  The vehicle may be damaged by an increase in charging voltage or temperature due to the high voltage current input.
For this reason, by monitoring the charging system voltage and temperature, overvoltage or overheating is detected, and charging is stopped if there is a malfunction in the charging system.
•  Quick charging is possible when all of the following conditions are met.
―  Parking lock is operated and shift lever is in P position.
―  SOC value is less than 100%
―  High voltage-related DTC is not output
―  Self-test of another function is not executed
―  Normal charge connector and quick charge connector are not connected at same time
―  Approx. 30 s (insulation check completed) have elapsed after inserting charge connector
•  When charging is started after the high voltage battery remaining distance to full discharge warning indication/warning light is turned on, the charging time up to 80% of full charge is approx. 40 min.
Note
•  The time required to charge the high voltage battery differs depending on the ambient temperature, high voltage battery temperature, state of charge, and years of use. In particular, charging takes longer under conditions in which the high voltage battery temperature and the ambient temperature are low.


Structural View

•  The charging system consists of the following main parts.
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Part name

Reference
Charge port assembly
(See CHARGE PORT ASSEMBLY / CHARGE LID BOX ASSEMBLY [(E)].)
Charge lid box assembly
Battery charge control Module
(See CHARGING CONTROL SYSTEM [(E)].)
Charge port-electrical supply unit


Operation


System operation at start of normal charging

1.  When the user connects the charge cable, the onboard charger detects that the charge cable has been connected and the battery charge control module is activated.

2.  CLPT communication between the charging equipment and the vehicle starts.

Note
•  CLPT communication is communication performed between the charging equipment and the vehicle.
Communication, such as the connection status of the charge cable, the availability of power supply, the maximum current that can be supplied, the presence or absence of a system malfunction, and the start and stop of charging, is performed.

3.  When the battery charge control module determines that the charging equipment is normal via CPLT communication, the battery charge control module sends a charging request signal to the PCM via CAN communication.

4.  The PCM operates when a charging request signal is received from the battery charge control module.

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5.  When the PCM turns on the high voltage contactors, the BECM operates, and it sends information about the high voltage battery to the PCM via CAN communication.

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6.  The PCM sends a charging request to the onboard charger.

7.  The onboard charger requests power supply to the charging equipment based on the CPLT signal.

8.  Power supply from the charging equipment starts.

9.  When the alternating current supplied from the charging equipment is input to the onboard charger, the AC/DC converter in the onboard charger starts converting alternating current to direct current.

10.  The current converted from alternating current to direct current is input to the high voltage battery through each fuse and contactor to charge the high voltage battery.

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System operation at end of normal charging

1.  The BECM monitors the status of the high voltage battery and it sends the high voltage battery information to the PCM via CAN communication.

When the PCM determines that the high voltage battery is sufficiently charged, it sends a charging finished signal to each module via CAN communication.

2.  The PCM withdraws the charging request to the onboard charger and requests that the onboard charger stop the power conversion.

3.  The onboard charger receives the request to stop the power conversion, gradually reduces the input current, and then stops the power conversion.

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4.  The PCM turns off the high voltage contactors. Turning off the high voltage contactor turns off the BECM.

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5.  The PCM and the battery charge control module are turned off by the PCM and the battery charge control module stopping CAN communication.

6.  Charging also stops when the user unplugs the charging plug.

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System operation at start of quick charging

1.  When the user connects the charge cable, the battery charge control module is operated by the detection of the charge cable as being connected.

2.  CLPT communication between the charging equipment and the vehicle starts.

Note
•  CLPT communication is communication performed between the charging equipment and the vehicle.
Communication, such as the connection status of the charge cable, the availability of power supply, the maximum current that can be supplied, the presence or absence of a system malfunction, and the start and stop of charging, is performed.

3.  When the battery charge control module determines that the charging equipment is normal via CPLT communication, the battery charge control module sends a charging request signal to the PCM via CAN communication.

4.  The PCM operates when a charging request signal is received from the battery charge control module.

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5.  When the PCM turns on the high voltage contactors, the BECM operates, and it sends information about the high voltage battery to the PCM via CAN communication.

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6.  When the PCM turns on the QBC (Quick Battery Charge) contactor, the charging indication value is sent to the charging equipment via CPLT communication through the battery charge control module.

7.  Power supply from the charging equipment starts.

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8.  The direct current supplied from the charging equipment is input to the high voltage battery through each fuse and contactor to charge the high voltage battery.

The quick charging circuit contains a QBC (Quick Battery Charge) voltage sensor.

By monitoring the voltage of the rapid charging circuit using the QBC (Quick Battery Charge) voltage sensor, the PCM protects the vehicle by cutting off the high voltage contactors if a malfunction occurs such as overvoltage.

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System operation at end of quick charging

1.  The BECM monitors the status of the high voltage battery and it sends the high voltage battery information to the PCM via CAN communication.

When the PCM determines that the high voltage battery is sufficiently charged, it sends a charging finished signal to each module via CAN communication.

2.  When the charging finished signal from the PCM is input to the charging equipment via CPLT communication through the battery charge control module, the charging equipment stops supplying power.

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3.  The PCM turns off the high voltage contactors, QBC (Quick Battery Charge) contactor, and the high voltage contactor. Turning off the high voltage contactor turns off the BECM.

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4.  The PCM and the battery charge control module are turned off by the PCM and the battery charge control module stopping CAN communication.

5.  Charging also stops when the user unplugs the charging plug.

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