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Ford Ranger EV (2001 year). Manual - part 102

414-03A-4

High Voltage/Traction Battery

DESCRIPTION AND OPERATION (Continued)

Battery Controller Module (BCM)

The traction battery contains 39 lead acid battery

The BCM is a combination low and high-voltage

modules, a battery controller module (BCM), a

module that controls all traction battery system

contactor box, a cooling system, a heating system,

operations. The BCM monitors the temperature and

and all necessary wiring. The 39 battery modules

state of charge for the 39 battery modules, controls

are wired together in series in order to achieve the

traction battery charging, cooling, and heating. The

necessary 312 volts (nominal) of direct current (DC)

module also calculates the maximum source and

required for vehicle operation. The battery modules

sink currents to ensure safe and reliable pack

are stacked in the tray and are separated into an

performance.

upper and lower level. The BCM is located in the
upper front end of the pack. The contactor box is

High Voltage Power Distribution Box (HVPDB)

in the upper rear end of the pack. Both the BCM

The HVPDB is located on top of the traction battery

and the contactor box are held in place using strips

charger in the underhood compartment. The

of Velcro

. The cooling system uses a two-speed

HVPDB distributes high-voltage to the DC/DC

blower that is located in the center of the traction

converter, heating system, air conditioning system,

battery pack. The fan circulates air through the

power steering system, and the battery charger. The

battery pack during charging in order to control

box contains fuses to protect the circuits to which

traction battery temperature.

the high-voltage is supplied. The box uses a

The traction battery heating system is used in cold

protective cover that is part of the interlock circuit.

weather locations. The lower level of battery

When the cover is removed, a limit switch will

modules is heated by a large heating element that

open the relays in the contactor box to interrupt

lays across the bottom of the supporting tray. The

high-voltage to the vehicle.

upper levels have individual heating elements

Emergency Power Off (EPO) / Interlock System

attached to each module. The heating elements are

The Electric Ranger is equipped with a power off

controlled by the BCM. The BCM will operate the

system that operates in a manner similar to that of a

heater elements when the vehicle is connected to a

gasoline powered vehicle. When the inertia switch is

charging station and the temperature is below 15

triggered, the EPO is activated and the contactor

(59

F). The BCM will turn the heating system off

box will disable all vehicle power. The power reset

when the temperature rises above 25

C (77

F).

light will illuminate to indicate that this situation

The traction battery uses a combination of high and

exists. The inertia switch must be reset before the

low-voltage wiring. The high-voltage wiring is

contactor box will re-activate the vehicle power.

identified by its orange color or orange wrapping.

Leakage Detection

The high-voltage circuit is protected by a 500 volt,

The battery controller module (BCM) monitors

250 amp fuse. The low-voltage harness serves as

current leakage between traction battery positive and

an interface with the rest of the vehicle. This

negative terminals and the vehicle chassis. If the

harness connects the vehicle through a 76-pin

detected leakage is below 50k ohms, the BCM will

connector, located on the LH front of the traction

request the interface adapter assembly (IAA) to

battery.

illuminate the electrical hazard warning light. The

Contactor Box

BCM monitors the leakage rate once every 20

The contactor box contains relays that switch the

seconds to ensure safety against electrical hazards

high-voltage power on and off. The relays shut off

and to ensure that it is safe to charge the vehicle.

high-voltage when the ignition key is in the OFF
position or 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 charging, battery heater, and
high-voltage auxiliary circuits.

414-03A-5

High Voltage/Traction Battery

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:

Refer to

Section 100-07

•

DTC C1862 Contactor Circuit Failure
— The interface adapter assembly (IAA) module

controls the auxiliary contactor to provide
high-voltage power to the high-voltage
auxiliary loads. The IAA module closes the
auxiliary contactor 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
open when it should be closed and closed
when it should be open.

Symptom Chart

Condition

Possible Sources

Action

•

DTC C1862 Contactor Circuit

•

Circuit(s).

•

GO to Pinpoint Test A.

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

Traction Battery High-Voltage Service Cord 418-F218

Face Shield 100-F035 or equivalent

Traction Battery Low-Voltage Service Cord 418-F219

(Continued)

414-03A-6

High Voltage/Traction Battery

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, TRACTION INVERTER MODULE (TIM), AND BATTERY

CONTROL MODULE (BCM) DIAGNOSTIC TROUBLE CODES

(DTCs)

NOTE: Do not go to test step A2 unless there is a multiple auxiliary load

Yes =

REFER to Pinpoint Test A

failure and DTC C1862 occurs after the IAA module on-demand self-test is

in Main/Precharge Contactor

performed.

Relay Control in this

•

Retrieve continuous DTCs from the TIM and perform on-demand

section.

self-test for the IAA module and BCM.

•

Do IAA module DTCs C1862 Contactor Circuit Failure and U2015

No =

GO to A2.

Signal Link Fault (Non SCP), TIM DTC B1676 Battery Pack Voltage

Out of Range, and BCM DTC C1837 Battery Heater Circuit Failure

all occur?

If other BCM DTCs occur,

REFER to the BCM DTC

Index in Section 100-07.

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 performing this test step.

•

With key OFF, monitor BCM PID CHGCORD.

•

Does the CHGCORD PID indicate OUT?

No =

RETRIEVE DTCs from the

BCM. REFER to Section

100-07.

A5 VERIFY AVAILABILITY OF AUXILIARY HIGH-VOLTAGE BUS

•

With key ON, monitor IAA module PID AUXHVB.

Yes =

REPLACE the IAA module.

REFER to Section 412-04.

•

Does the AUXHVB PID indicate AVAILA?

No =

RETRIEVE DTCs from the

BCM. REFER to Section

100-07.

A6 CHECK AUXILIARY CONTACTOR RELAY FAULT STATUS

(Continued)

414-03A-7

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE

TEST STEP

ACTION TO TAKE

•

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?

A7.
If AUX HVC PID

indicates OFAULT, GO to

A14.

A7 CHECK AUXILIARY CONTACTOR RELAY CONTROL SIGNAL

(CLOSE FAULT)

•

Connect 104-Pin Breakout Box (BOB) to IAA module and IAA module

Yes =

GO to A10.

C1945.

•

Enter IAA module active command mode AUXILIARY SYSTEM

No =

GO to A8.

CONTROL, set the active command AUX CONT to OPEN, and measure

the voltage between BOB pin 42 and ground (BOB pin 80).

•

Is the voltage less than 1 volt?

A8 CHECK CIRCUIT 3998 (GY) FOR SHORT TO POWER

•

Disconnect BOB from IAA module; leave BOB connected to IAA

Yes =

GO to A9.

module C1945.

•

With key ON, measure the voltage between BOB pin 42 and ground

No =

REPLACE the IAA module.

(BOB pin 80).

REFER to Section 412-04.

•

Is the voltage greater than 0 volts?

A9 CHECK CIRCUIT 3998 (GY) BETWEEN IAA MODULE AND

TRACTION BATTERY SUPPORT TRAY FOR SHORT TO POWER

•

With key OFF, disconnect traction battery support tray in-line C1939.

Yes =

REPAIR the GY wire

between the IAA module

and in-line C1939M.

•

With key ON, measure the voltage between BOB pin 42 and ground

No =

REMOVE the traction

(BOB pin 80).

battery and REPAIR the GY

•

Is the voltage greater than 0 volts?

wire between the contactor

box and in-line C1939F.

A10 CHECK AUXILIARY CONTACTOR RELAY STATUS SIGNAL

(CLOSE FAULT)

•

Enter IAA module active command mode AUXILIARY SYSTEM

Yes =

GO to A11.

CONTROL, set the active command AUX CONT to OPEN, and measure

the voltage between BOB pin 26 and ground (BOB pin 80).

•

Is the voltage greater than 10 volts?

No =

GO to A13.

A11 CHECK CIRCUIT 3999 (DB/LG) BETWEEN IAA MODULE AND

TRACTION BATTERY SUPPORT TRAY FOR SHORT TO POWER

•

Disconnect BOB from IAA module; leave BOB connected to IAA

Yes =

REPAIR the DB/LG wire

module C1945.

between the IAA module

and in-line C1939M.

•

With key OFF, disconnect traction battery support tray in-line C1939.

No =

GO to A12.

•

With key ON, measure the voltage between BOB pin 26 and ground

(BOB pin 80).

•

Is the voltage greater than 0 volts?

A12 CHECK CIRCUIT 3999 (DB/LG) BETWEEN CONTACTOR BOX

AND TRACTION BATTERY SUPPORT TRAY FOR SHORT TO

POWER

•

Disconnect BOB from IAA module C1945.

Yes =

REPAIR the DB/LG wire

between the contactor box

and in-line C1939F.

(Continued)

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