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Ford Ranger EV (2001 year). Manual - part 152

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

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

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:

Refer to

Section 100-07

•

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

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)

414-03B-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 =

REFER to Pinpoint Test A

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

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

•

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.

(Continued)

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