Ford Ranger EV (2001 year). Manual — part 152
414-03B-4
414-03B-4
High Voltage/Traction Battery — Nickel Metal Hydride
Battery Controller Module (BCM)
DESCRIPTION AND OPERATION
The BCM is a combination low and high-voltage
High Voltage/Traction Battery
module that controls all traction battery system
The traction battery is the primary source of power
operations. The BCM monitors selected battery
for the Ranger EV. It is located between the frame
module temperatures, state of charge for the 25
rails and underneath the vehicle. The supporting tray
battery modules, and controls traction battery
contains all of the traction battery components. The
charging and cooling. The module also calculates
tray is made of a strong, non-conductive composite
the maximum source and sink currents to ensure
material and has brackets molded into it at various
safe and reliable pack performance.
locations. The traction battery, when fully loaded
High Voltage Power Distribution Box (HVPDB)
with all necessary components, weighs 595 kg
The HVPDB is located on top of the traction battery
(1,310 lb). The NiMH traction battery components
charger in the underhood compartment. The
are not interchangeable with the lead acid traction
HVPDB distributes high-voltage to the DC/DC
battery components. The NiMH traction battery is
converter, vehicle heating system, air conditioning
identified by its green label.
system, power steering system, and the traction
The traction battery contains 25 nickel metal
battery charger. The box contains fuses to protect
hydride battery modules, a battery controller module
the circuits to which the high-voltage is supplied.
(BCM), the independent observer module (IOM ), a
The box uses a protective cover that is part of the
contactor box, a cooling system, and all necessary
interlock circuit. When the cover is removed, a limit
wiring. The 25 battery modules are wired together
switch will open the relays in the contactor box to
in series in order to achieve the necessary 300 volts
interrupt high-voltage to the vehicle.
(nominal) of direct current (DC) required for vehicle
Independent Observer Module (IOM)
operation. The BCM and the IOM are located in the
The IOM is a module that monitors the traction
front end of the pack. The contactor box is in the
battery temperature during charging using its own
rear end of the pack. The cooling system uses two
independent thermistors. In the event that the IOM
blowers to circulate fresh, cool air through the
detects a battery pack over-temperature condition, it
battery pack. The flow through blower, which is
will interrupt the pilot signal to the BCM. This
mounted in the front of the battery pack, brings
event will cause an interruption of vehicle charging.
fresh air into the pack. The recirculating blower is
located in the center of the battery pack and
Pilot signal from the PCS of the IOM is as follows:
circulates air throughout the battery pack.
•
When the vehicle is plugged into the power
The traction battery uses a combination of high and
control station PCS, a squarewave pilot signal is
low-voltage wiring. The high-voltage wiring is
sent through the charge cord to the IOM via the
identified by its orange color or orange wrapping.
charge inlet.
The high-voltage circuit is protected by a 500 volt,
•
If the IOM determines that the battery temperature
250 amp fuse. The low-voltage harness serves as
is within normal charging parameters, it allows
an interface with the rest of the vehicle. This
the pilot signal to pass to the onboard battery
harness connects the vehicle through the 76-pin
charger and then to the BCM.
connector, located on the LH front of the traction
battery.
•
The BCM receives the signal from the charge
inlet door switch notifying it that the vehicle has
Contactor Box
been plugged in.
The contactor box contains relays that switch the
•
Once the BCM receives the plugged in signal
high-voltage on and off. The relays shut off
from the charge inlet door switch, it sends fault
high-voltage when the ignition key is in the OFF
detection signals to the IOM to determine if there
position, when the vehicle is being charged, or
are any faults.
when the inertia switch has been tripped. The
contactor box also contains the pre-charge circuits,
battery pack current sensing circuitry, and fuses to
protect the charger, and high-voltage auxiliary
circuits.
414-03B-5
414-03B-5
High Voltage/Traction Battery — Nickel Metal Hydride
DESCRIPTION AND OPERATION (Continued)
•
If the BCM receives a normal fault detection
•
To unlatch the IOM, the auxiliary battery negative
signal (no faults present) from the IOM, it
cable must be removed for 30 seconds. Once this
activates the onboard charger and the traction
is done, the vehicle will again charge normally.
battery is charged.
•
After unlatching, the DTC must still be cleared
from the BCM memory using a scan tool.
Operation During Over Temperature Conditions
In the event an IOM temperature sensor detects an
•
If, after unlatching the IOM, the fault resets
over-temperature or a rapid rise in temperature, it
immediately, the source of the concern is likely a
will interrupt the pilot signal and prevent the BCM
failed temperature sensor or its circuit.
from activating the onboard charger.
•
After the IOM has been unlatched, if the fault
In the event an over-temperature condition occurs
resets after the vehicle has been charging for
that does not include a rapid temperature rise,
some time, the source is likely a rapid rise in
charging will be interrupted but no DTC will be set.
temperature.
Charging will resume once the battery pack
NOTE: Using a scan tool to monitor the BCM
temperature returns to normal.
temperatures should allow the concern to be
If an IOM temperature sensor registers 49 degrees
verified.
Celsius (120 degrees Fahrenheit) or greater, an
NOTE: The vehicle will be unable to continue
over-temperature condition will be identified. The
charging if the IOM goes into a latched condition.
over-temperature condition will exist until the
Repair the source of the fault before resuming
lowest temperature sensor reading is at or below 45
traction battery charging.
degrees Celsius (113 degrees Fahrenheit).
NOTE: Most all concerns with the IOM are sensor
The BCM will suspend traction battery charging if
related.
any BCM temperature sensor exceeds 45 degrees
Emergency Power Off (EPO) / Interlock System
Celsius (113 degrees Fahrenheit). The BCM will
The Electric Ranger is equipped with a power off
allow charging to resume once the lowest BCM
system that operates in a manner similar to that of a
temperature sensor reading is at or below 42
gasoline powered vehicle. When the inertia switch is
degrees Celsius (108 degrees Fahrenheit).
triggered, the EPO is activated and the contactor
If the cause of the interruption is a rapid rise in
box will disable all vehicle power. The power reset
temperature or an open or shorted temperature
light will illuminate to indicate that this situation
sensor, a signal will be sent from the IOM to the
exists. The inertia switch must be reset before the
BCM indicating a fault condition. This will cause
contactor box will re-activate the vehicle power.
the BCM to store a DTC. The parameter for a
rapid rise in temperature is two degrees Celsius (3.6
Leakage Detection
degrees Fahrenheit) within six minutes at any IOM
The battery controller module (BCM) monitors
temperature sensor.
current leakage between traction battery positive and
negative terminals and the vehicle chassis. If the
•
An interruption of the pilot signal will be detected
leakage resistance drops below 50 k ohms, the
using the OPSTATE _PID referred to in the
BCM will request the interface adapter assembly
diagnostic procedures in this section.
(IAA) to illuminate the electrical hazard warning
•
If a DTC is sent in the BCM by the IOM because
light. The BCM monitors the leakage rate once
of a rapid rise in temperature or sensor fault, the
every 20 seconds to ensure safety against electrical
IOM will be latched.
hazards and to ensure that it is safe to charge the
vehicle.
•
Once latched, the IOM will prevent charging until
it is unlatched.
414-03B-6
414-03B-6
High Voltage/Traction Battery — Nickel Metal Hydride
Electrical Schematic
DIAGNOSIS AND TESTING
Auxiliary Contactor Relay Control
Refer to Electrical and Vacuum Troubleshooting
Manual, Cell 21, Contactor Box Relay Control for
Diagnostic Trouble Code (DTC) Definition
schematic and connector information.
The following DTC relates to the control of the
Inspection and Verification
auxiliary contactor relay:
•
DTC C1862 Contactor Circuit Failure
— The interface adapter assembly (IAA) module
controls the auxiliary contactor relay to
provide high-voltage power to the high-voltage
auxiliary loads. The IAA module closes the
auxiliary contactor relay when the ignition key
is turned to the ON position and monitors its
status through a feedback line from the
contactor box. The IAA module sets DTC
C1862 if it detects the auxiliary contactor
relay open when it should be closed and
closed when it should be open.
Symptom Chart
Symptom Chart
Condition
Possible Sources
Action
•
DTC C1862 Contactor Circuit
•
Circuit(s).
•
Failure
•
Interface adapter assembly
(IAA) module.
•
High-voltage power
distribution box (HVPDB).
•
Contactor box.
•
Contactor box high-voltage
fuse.
Special Tool(s)
Pinpoint Tests
Traction Battery High-Voltage Lockout and Diagnostic
Special Tool(s)
Tool 418-F207
104-Pin Breakout Box (BOB) 418-049 (014-00950) or
High-Voltage Insulated Safety Gloves 100-F036 or
equivalent
equivalent
Traction Battery High-Voltage Service Cord 418-F218
Face Shield 100-F035 or equivalent
Traction Battery Low-Voltage Service Cord 418-F219
(Continued)
414-03B-7
414-03B-7
High Voltage/Traction Battery — Nickel Metal Hydride
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE
TEST STEP
ACTION TO TAKE
A1 CHECK FOR INTERFACE ADAPTER ASSEMBLY (IAA)
MODULE AND TRACTION INVERTER MODULE (TIM)
DIAGNOSTIC TROUBLE CODES (DTCs)
NOTE: Do not go to test step A2 unless there is a multiple auxiliary load
Yes =
failure and DTC C1862 occurs after the IAA module on-demand self-test is
in Main/Precharge Contactor
carried out.
Relay Control in this
•
Retrieve continuous DTCs from the TIM and carry out the on-demand
section.
self-test for the IAA module.
•
Do IAA module DTCs C1862 Contactor Circuit Failure and U2015
No =
GO to A2.
Signal Link Fault (Non SCP), and TIM DTC B1676 Battery Pack
Voltage Out of Range all occur?
A2 CHECK HIGH-VOLTAGE AUXILIARY BUS STATUS
•
With key ON, monitor IAA module PID AUXHVB.
Yes =
GO to A3.
•
Does the AUXHVB PID indicate AVAILA?
No =
If AUXHVB PID indicates
UNAVAI, RETRIEVE
DTCs from the battery
control module (BCM).
REFER to Section 100-07.
If AUXHVB PID indicates
EPO or INERSW, REFER
to Emergency Power Off
(EPO)/Interlock System in
this section.
A3 CHECK AUXILIARY CONTACTOR RELAY STATUS
•
With key ON, monitor IAA module PID AUX HVC.
Yes =
System OK. CHECK wiring
for intermittent connections.
•
Does the AUX HVC PID indicate CLOSED?
No =
If AUX HVC PID
indicates OPEN, GO to A4.
If AUX HVC PID
indicates OFAULT, GO to
A6.
A4 CHECK CHARGER CORD STATUS
NOTE: Verify the power control station (PCS) charger cord is not plugged
Yes =
GO to A5.
into the charger inlet before carrying out this test step.
•
With key OFF, monitor BCM PID CHGCORD.
•
Does the CHGCORD PID indicate OUT?
No =
RETRIEVE DTCs from the
A5 VERIFY AVAILABILITY OF AUXILIARY HIGH-VOLTAGE BUS
•
With key ON, monitor IAA module PID AUXHVB.
Yes =
REPLACE the IAA module.
•
Does the AUXHVB PID indicate AVAILA?
No =
RETRIEVE DTCs from the
A6 CHECK AUXILIARY CONTACTOR RELAY FAULT STATUS
•
Enter IAA module active command mode AUXILIARY SYSTEM
Yes =
System OK. CHECK wiring
CONTROL, monitor IAA module PID AUX HVC, and set the active
for intermittent connections.
command AUX CONT to CLOSE.
•
After the CLOSE signal is complete, set the active command AUX
No =
If AUX HVC PID
CONT to OPEN.
indicates CFAULT, GO to
•
Does the AUX HVC PID indicate CLOSED?
(Continued)
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