Service Information

Category

3-1, Shinchi, Fuchu-cho, Aki-gun

Hiroshima 730-8670, Japan
TEL : 81(82)287-5323
FAX : 81(82)287-5220

Technical

G
Coverage

Ref. No.

Page

E001/13

1 of 9

Date Issued

Distributor only

Please inform your dealers

Please convey this information to your

Warranty Dept.
Parts Dept.

Director
Training Dept.

Applicable Model

February 1, 2013
General Manager
Field Rep.

Date Revised

Applicable Countries or Specifications

Mazda6 (GJ) with i-ELOOP

Worldwide

Subject: Basic knowledge on i-ELOOP

DESCRIPTION
This is to inform you of the basic knowledge and maintenance on newly-adopted i-ELOOP
system.
1. Summary
For the purpose of fuel economy improvement, electricity is generated using kinetic energy
during deceleration to recover it as electrical energy which reduces amount of fuel that is used
for electric supply.
The Mazda-unique regenerative braking system enables us to store, extract and use huge
amount of energy during deceleration instantly by using a capacitor. Through efficient energy
regeneration, storage, and usage, fuel economy improvement is expected during actual driving.
[Reference]
Typically, engine consumes 5-15% fuel for electrical generation. Deceleration regeneration
system uses kinetic energy that has been emitted in vain during deceleration and generates
electricity without consuming fuel to contribute to fuel economy improvement.

2. Structure
(1) Structural view

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(2) System wiring diagram

*1: Audio amplifier, Bluetooth unit (vehicle with Bluetooth system), audio unit, climate control
unit (vehicle with auto A/C), parking sensor control module (vehicle with parking sensor
system), instrument cluster, rear mount camera, clock (vehicle with manual A/C)
*2: Electrical devices other than electrical device *1
*3: SKYACTIV-G 2.0, SKYACTIV-G 2.5
*4: SKYACTIV-D 2.2

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(3) Detail of components
Generator
It is a variable-voltage generator that can generate a voltage of 12-25V during deceleration to
charge the capacitor. At normal operation 12 V are generated.
PCM is monitoring the capacitor voltage and electricity is generated when PCM concludes
that capacitor voltage decreases.
Capacitor
10 electrical accumulators (electrical double-layer capacitor) that can charge/discharge high
current instantly are connected in series. 25V charge can be physically stored.
As ion molecules store electric charge, degradation due to charge/discharge is few.
It can endure about 1 million times of rapid charge/discharge cycles.

Principle of the capacitor

The electrical double layer capacitor is a system in which electric
charge is stored performing ionic adsorption and desorption in
electrolyte to electrode.
Positive
electrode

Negative
electrode

Collective
electrode

Charge

Electrode
(Activated
carbon)

Electrolyte

Discharge
: Anions
: Cations

Separator
Electrical double layer

DC-DC converter
When the generator produces the maximum voltage (25V), it is reduced to 12V with DC-DC
converter so that applicable voltage can be supplied to electrical devices.
[During regeneration]
14-25V voltage stored in the capacitor is converted through DC-DC converter.
[During i-stop]
During i-stop, capacitor voltage is converted to 11.5 to 12.5V by DC-DC converter.
When restarting the engine, i-stop relay is turned off to retain source voltage of meter/audio
systems that lie downstream of DC-DC converter.
Power source for other electrical devices such as starter is supplied from the battery.
[If consumption current is 50A or more]
If consumption current of vehicle electrical devices exceeds 50A or
more, bypass relay is turned on to supply voltage generated by
generator (14.8V) to those electrical devices directly.
In this case, movement of i-ELOOP gauge on the combination meter
becomes slow, but this is not a failure.

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3. Operation
The i-ELOOP operation mode varies depending on the vehicle driving condition and status of
electrical devices related to i-ELOOP system.
When the driver lifts his/her foot off the accelerator pedal, variable voltage-type generator
generates electricity to store it in the capacitor. It takes only a few seconds to charge the
capacitor to the full. Voltage of electricity stored in the capacitor is reduced to 12V with DC/DC
converter for power supply to various electric devices.

The following are examples of the i-ELOOP operation in each mode.

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(1) Regenerative braking mode
During fuel-cut by release of accelerator
pedal and TCC (Torque Converter Clutch)
engagement, generator is activated to store
electricity to the capacitor. Voltage stored in
the capacitor is reduced at DC-DC converter
to for power-supply to each vehicle part.
To prevent deceleration electricity from
increasing due to power generation, such
power generation is controlled by PCM.

(2) Conventional power generation mode (no

regenerative braking)
When battery voltage becomes 14V or less
while engine running, generator is activated
to store 12 to 25V electricity to the capacitor.
Voltage stored in the capacitor is reduced
with DC-DC converter for power-supply to
each vehicle electrical device.
Generators output is lower than that of
regenerative power generation mode.

(3) Capacitor (i-ELOOP) power supply mode

If capacitor voltage exceeds battery voltage,
voltage stored in the capacitor is reduced
with DC-DC converter for applicable
power-supply to each electrical device (IG1,
IG2 power source) on the vehicle.

(4) Battery power supply mode

In case capacitor voltage falls below the
capacitors designed minimum voltage
(14-17.5V *It varies depending on the
capacitors degradation condition) during
i-stop operation, or in case of cranking,
electrical power is supplied from the battery
to each electrical device on the vehicle.

(5) i-stop mode (Engine restart)

The i-stop relay in DC-DC converter is shut
off during engine restart to avoid supply of
electrical power from the capacitor to the
battery, as battery voltage has been reduced
due to cranking.
Electrical power source is split into battery
and capacitor to ensure electrical power is
supplied to meter/audio system etc.

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(6) By-pass mode
When vehicle electrical load (consumption
current) exceeds 50A or more, bypass relay
within DC-DC converter is turned on for
supplying electricity generated by generator
to vehicle electrical devices directly.
Also, in case DC-DC converters voltage
reduction circuit is failed, or in case it is
anticipated that battery voltage cannot
guarantee minimum 11V, it is switched to
bypass mode.
[Reference]
During the bypass mode, verification is not possible using the instrument cluster indication.
(7) Pre-charge mode
If the vehicle is left for a long time without
running the engine or if self-discharge of
capacitor such as excessive dark current is
continued, capacitors voltage decreases. In
such case, electrical power is supplied from
the battery or the generator to the capacitor
due to the following reasons.
1) To secure generators initial excitation
current that is supplied from the capacitor.
2) In order to supply electrical power source from the capacitor, capacitors electric potential
needs to be higher than that of battery.
Operation is different depending on the condition.
Capacitor voltage

Ignition switch: ON OFF

(Engine ON or OFF)

Ignition switch: ON
(Engine ON or OFF)

3.5V or less
(Due to ensuring
initial exciting
voltage of the
generator.)

The capacitor is charged

up to 3.5V from the battery
by control of the DC-DC
converter.

The capacitor is
charged up to 4.5V
from the battery by
control of the PCM.

3.5V 9.5V
(Due to outputting
the current from
DC-DC converter.)

The capacitor isnt charged from the battery.

(Because the generator can be operating when
the engine on.)

9.5V or more

Instrument cluster display

Applicable
(A message is displayed
when the voltage of the
capacitor is 9.5V or less
and the engine is started.)
(A message wont be
displayed when the
DC-DC converter supplies
the voltage.)
Not applicable

It stops when capacitor voltage is increased with electric voltage delivered from DC-DC
converter.
(8) Capacitor (i-ELOOP) power generation mode
When capacitor voltage exceeds 20V or more
(16V or more if battery output is decreased)
with engine switch OFF + bonnet closed,
extra voltage owned by the capacitor is
charged to the battery.

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4. Instrument cluster display
PCM sends a signal to the combination meter in terms of Regenerative power generation
condition through i-ELOOP /Output of regenerative power generation/ Capacitor storage. Then,
information related to i-ELOOP is indicated on the liquid crystal screen.

Regenerative braking power

Displays the direction in which power is moving
generation condition gauge
from the regenerative braking power generation.
Regenerative braking power
Displays the amount of power generated by
2
generation amount gauge
regenerative braking.
Capacitor accumulation
Displays the amount of electrical power stored in
3
amount gauge
the capacitor.
To indicate capacitor storage, amount of electric energy stored in the capacitor is calculated
based on DC-DC converter input terminal voltage and electric current sensor within DC-DC
converter etc.
1

5. i-stop operating condition

Different or additional i-stop operating conditions compared to other models due to i-ELOOP
installation are as follows.
DC-DC converter (i-ELOOP) PWR3
25 A or less
output current
i-ELOOP bypass mode operational Not DC-DC converter overheats condition.
condition
If its overheat condition, bypass mode is activated.
Capacitor voltage has to be more than the
Capacitor voltage
capacitors designed minimum voltage(1417.5V).
6. In case vehicle isnt driven for a long time (about 1 month) and in case of capacitor
replacement
In case capacitor self-discharge is continued (vehicle left for a long time without running the
engine)/dark current is excessive, voltage stored in the capacitor decreases. In order to supply
electrical power from the capacitor, capacitors electric charge needs to be higher than that of
the battery. Therefore, pre-charge mode starts to charge the capacitor as described the above.
During pre-charge mode, the message shown on liquid crystal screen in
the meter is changed as shown on the right.
It takes several to 30 seconds to complete charging. During charging (until
the message on screen disappears), electric power is supplied only from
the battery. Then, you may feel the electric power steering operation is
heavy depending on the battery condition. Thats why we recommend
users not to drive the vehicle during charging period. If you drive the
vehicle, you will hear warning tone. Also, if message on the liquid screen
isnt turned off regardless of waiting 3 minutes or more, it indicates a
system malfunction, which will turn the master warning lamp on.

NOTE: Message might

be different.

When pre-charge mode is activated, you can see the mileage as of pre-charge occurrence by
monitoring PCM data PRE_CHG_DIS with M-MDS.
When capacitor is replaced, pre-charge mode is activated because voltage in the capacitor is
low.

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If you use the vehicle as demonstration car, be sure to charge the battery regularly as usual.
Capacitor is charged only through supply from the generator. If you want to prevent the vehicle
from going into the pre-charge mode, start the engine once per two weeks and push the
accelerator pedal several times to charge the capacitor.
7. How to fix dead battery
If the battery is completely discharged due to lights not being turned off mistakenly and you
jump-start the engine with the booster cables, make sure the cables are connected for 3 minutes
approximately even after engine starts, in order to wait until the battery voltage is raised. If you
start the engine, remove the booster cables and drive the car immediately while battery voltage
is still low, DTC showing voltage decrease is stored.
8. Things to keep in mind during maintenance work
If terminals of the following i-ELOOP related parts hit the vehicle body with the capacitor service
plug installed, it may cause fire or failure of electrical parts. When you separate the following
terminals, be sure to remove the capacitors service plug before the separation.
-

Capacitors battery cable terminal

Capacitors engine harness terminal
DC-DC converters battery cable terminal
Generator B terminal

(2)
(1)

(3)

Service plug
Bolt

(1) Remove the bolt

(2) Pull out the service plug
(3) Fasten the removed bolt

When you cause short circuit by mistake, replace the fuse on top of the service plug because
such fuse is melted.
9. Things to keep in mind when storing/transporting capacitor
- If the capacitor is stored as a part (new part, replacement part for claim), please follow the
precautions described on the packaging box. If its stored in laterally-facing or
downward-facing directions, electrolyte solution in the capacitor may flow into pressure
regulation valve, which may cause valve seizure.
- Avoid agitation of parts
If part is dropped and seems to have breakage or deformation on the surface, replace it.
- Service parts are delivered with short wiring harness attached to prevent electrification.
Remove the short wiring harness after the part is installed
on the vehicle.
- If it is kept and sent as warranty claim parts, remove the
service plug, fix it with the removed bolt, fasten the area
around bolt with vinyl tape etc., and store it in the original
packaging., because the installation bolt may be removed
during transportation, which may make the service plug to
go back to the original position.
- Capacitor that is stocked as repair part must be used
within 2 years after production date.
Production date is indicated on the outer case of the repair
part.
Fix the service plug with
vinyl tape attached.

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10. Capacitor disposal
Capacitor reserves electric charge as the battery does.
If the vehicle or the part is discarded (disassembled) while the capacitor (i-ELOOP) is still
charged with electricity, spark or fire may occur due to electricity stored in the capacitor. When
you dispose the vehicle or the part, be sure to conduct the forcible discharge of the capacitor as
follows before disposal.
LED

Connector

Plug

Plug
Connector

Discharge box

LED
illuminates

Discharge
box cover

(1)
(2)
(3)
(4)
(5)

Remove the discharge box cover.

Connect the connector in the discharge box to the plug.
Verify that the LED which displays during discharging is displayed.
Verify that the LED turns off.
Dispose the capacitor.

Mitsunori Tokunaga
Manager, Technical Information Gr.
Technical Service Dept.
Mazda Motor Corporation