Plug-In Charging System Description and Operation
Plug-In Charging System components
The high voltage battery charging system consists of four main components: The drive motor battery charger cable, the hybrid/EV battery charger receptacle, often referred to as the drive motor battery charger receptacle, the battery charger, often referred to as the drive motor battery charger, and the hybrid/EV battery pack. A variety of mechanical, visual and audio indicators/devices are used to communicate/interface with the customer or other user of the charging equipment.
Drive Motor Battery Charger Equipment
The drive motor battery charger cable provided with the vehicle features a standard household electrical plug on one end and a plug designed to interface with the hybrid/EV battery charger receptacle on the other end. The drive motor battery charger cable features a charge current interrupt device with AC power, fault and missing ground indicators, and it is stored beneath the vehicle's load floor. An optional charge station may be available to some customers who want to reduce the amount of time needed to recharge the high voltage battery. The optional charge station, if available, is hard-wired to a 230/240 V power supply and mounted to the wall in the customer's garage, and features the same plug on the vehicle end as the drive motor battery charger cable.
The Drive Motor Battery Charger Cable Indicators and the Vehicle Indicators
The drive motor battery charger cable has two indicators, the AC Present Indicator and the Fault Indicator. The AC Present Indicator becomes solid green when AC voltage is present at the wall plug. A flashing red AC Present Indicator means the AC voltage is out of range. Flashing red AC Present Indicator and Fault Indicator means the AC outlet does not have a proper safety ground and charging is not permitted for safety reasons. The Fault Indicator becomes solid red for a current trip or failed self check.
The battery charger is supervised and controlled by the hybrid/EV powertrain control module 2. The hybrid/EV powertrain control module 2 is the primary controller, and all diagnostic trouble codes will set in that module even though some of the diagnostics are actually run within the battery charger. Charging events can be delayed at customer request to take advantage of lower rates during non-peak hours. The status of charging events, including delays, is communicated to the user through visual indications, instrument panel mounted charge status indicator, and audio tones, charge status enunciator. The vehicle charge status indicator, located on the top middle of the instrument panel, will be solid green when the vehicle is charging under automatic control. It will have a fast flash green if the charging is delayed and will begin later. It will have a slow flash green when charging is complete. A solid yellow indicator means the vehicle is not able to accept a charge. If there is no indicator, the drive motor battery charger cable is not working properly or not connected.
Vehicle Receptacle
The vehicle receptacle, or hybrid/EV battery charger receptacle, is located behind the charging port door on the driver's side front fender. The receptacle is accessed by depressing a switch located on the inside of the driver's door.
Battery Charger
The battery charger is a serviceable assembly containing several micro-processors, two separate high voltage chargers and a single low voltage charger. It is mounted behind the passenger's side headlamp assembly, is programmable, and communicates via serial data. Engine coolant is used to ensure that the charger does not exceed its maximum designed operating temperature. The battery charger and the power inverter module, often referred to as the drive motor generator power inverter module, are cooled by a power electronics cooling loop, which is separate from other cooling systems. The low voltage charger is used to ensure that the 12 V battery does not become depleted during a charge event. One of the high voltage chargers is used while charging with a 120 V charge source, and both are used with a 230/240 V charge source.
Battery Maintenance Mode
Battery Maintenance Mode is an automatic function that prevents deep discharge of the 12 V battery in specific circumstances. It is enabled when the drive motor battery charger cable is plugged into the hybrid/EV battery charger receptacle and the hybrid/EV battery pack is not being charged. Operation differs depending on whether the power mode is Vehicle Off or Vehicle in Service Mode.
While Vehicle Off, the 12 V battery is monitored at periodic intervals up to a maximum of 30 days. While Vehicle in Service Mode, the 12 V battery is monitored at periodic intervals up to a maximum of 60 hours. If voltage is low, the 12 V battery is charged by the battery charger using external power for up to four hours. This function is only intended to prevent a dead 12 V battery and does not provide a full charge. This is more efficient than continuously trickle charging, thus minimizing the usage of external power.
Under normal circumstances, with a battery that is charged when the vehicle is parked, Battery Maintenance Mode will simply monitor the voltage level, and no charging will be necessary. With Vehicle Off, Battery Maintenance Mode will maintain the 12 V battery for up to 30 days. For longer periods, refer to Owner Manual for instructions.