Ford 2001 Ranger, Manual

Page: 607 / 1218

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.
2001 Ranger EV, 01/2001