Charging System - 1.0L EcoBoost (90kW/120PS)/1.6L EcoBoost (132kW/180PS) - Sigma - System Operation and Component Description

System Operation

System Diagram

Network Message Chart

  Module Network Input Messages — Body Control Module (BCM)

  Module Network Input Messages — Instrument Panel Cluster (IPC)

  Module Network Input Messages — Powertrain Control Module (PCM)

Charging System

The PCM -controlled, or Smart Charge charging system determines the optimal voltage setpoint for the charging system and communicates this information to the voltage regulator. The Smart Charge charging system is designed to set a DTC when a charging system fault is present. All of the Diagnostic Trouble Codes (DTCs) can set continuous faults, but not all Diagnostic Trouble Codes (DTCs) set as on-demand faults.

Some of the Parameter Identifications (PIDs) and their associated descriptions used in the charging system diagnosis are listed below:

This system uses a dedicated LIN communication circuit. The generator uses this LIN circuit to communicate the desired setpoint from the PCM to the voltage regulator. The generator also uses this LIN circuit to communicate the generator load and error conditions to the PCM .

The PCM simultaneously controls and monitors the generator output. When the current consumption is high or the battery is discharged, the PCM raises engine speed as needed to increase generator output. The generator charges the battery and at the same time supplies power for all required electrical loads. The battery is more effectively charged with a higher voltage when the battery is cold and a lower voltage when the battery is warm. The PCM uses a signal from the IAT sensor to adjust the charging voltage according to the battery temperature. The PCM also uses other inputs to control the charging system voltage such as the VSS and engine coolant temperature. The voltage setpoint is calculated by the PCM and communicated to the voltage regulator by the GENCOM circuit based on the needs of the vehicle and the conditions.

The PCM turns off the generator during cranking to reduce the generator load and improve cranking speed. Once the engine starts, the PCM slowly increases generator output to the desired voltage.

The PCM controls the charging system warning indicator by sending a message over the HS-CAN to the IPC . The IPC module turns the charging system warning indicator ON or OFF. The IPC will also send a message to the FCDIM (vehicles without Touch Screen display) or FDIM (vehicles with Touch Screen display) to display CHECK CHARGING SYSTEM. When the ignition is ON and the engine is off, the CHECK CHARGING SYSTEM message may not be displayed. For additional information regarding the IPC module,
Refer to: Message Center - System Operation and Component Description (413-01 Instrumentation, Message Center and Warning Chimes, Description and Operation).
For additional information regarding the FCDIM or FDIM , Refer to the appropriate section in Group 415 for the procedure.

Under certain circumstances the charging system may have a concern but still keep the battery charged and the vehicle running. The LIN normally initiates charging from the PCM , but the generator may continue charging when a fault is present on this circuit. If the engine is operated at greater than 2,000 rpm momentarily, the generator may self-excite or start charging on its own. The charging system warning indicator is illuminated and/or CHECK CHARGING SYSTEM message is displayed, and the generator operates in a default mode (approximately 13.5 volts) until the engine is turned off. When the engine is restarted and the engine is operated at greater than 2,000 rpm momentarily, the generator may again self-excite and again the charging system warning indicator is illuminated and/or CHECK CHARGING SYSTEM message is displayed.

Electrical Energy Management

NOTICE: When any vehicle module is being programmed, connect an external battery charger to make sure the module programming is completed without interruption due to the load shedding feature becoming active. The external battery charger must maintain a system voltage above 13 volts. This may require a charger setting higher than the lowest charge setting. The external battery charger negative connection must be made to an engine or vehicle chassis ground and not the negative battery terminal. If the connection is to the negative battery terminal, load shedding may begin and module programming may be corrupted. After charging has begun, start the engine to clear any load shed states and then turn the engine off and proceed with programming.

The Electrical Energy Management system software is housed in the BCM . It has the algorithms and control structure for the Smart Regenerative Charging, and Load Shed Control Strategy. The Electrical Energy Management system is equipped with a Battery Monitoring Sensor to monitor the battery.

This sensor serves as an input to the Electrical Energy Management software. If the sensor malfunction due to wiring issues or failure, a DTC sets. In most cases the Electrical Energy Management functions are turned off until the sensor operation is restored.

Battery State of Charge

During the drive cycle the Electrical Energy Management software adjusts he initial battery state of charge by monitoring the charge and discharge current and adjusting the state of charge up during charging, and down during discharge. During rest periods (key off with no electrical loads) when the vehicle enters sleep mode, the battery voltage is sampled to recalibrate the State of Charge. The sensor automatically executes this recalibration anytime the vehicle enters sleep mode and when the total vehicle current draw is below 300mA. It takes 4 to 6 hours in the sleep mode to recalibrate the battery state of charge to high accuracy. If the system draw does not allow the battery state of charge recalibration over the previous 7 to 10 days the State of Charge quality factor changes to flag this and some Electrical Energy Management Functions which rely on the accuracy of the battery state of charge may be temporarily turned off until a recalibration takes place.

NOTE: Any devices left attached to the power socket that draw in excess of 200mA (or less depending on other battery loads) prevents a battery monitoring sensor from recalibrating the battery state of charge.

Engine Off Load Shed

The BCM uses the battery monitoring sensor to keep track of the battery state of charge. When the engine is off and the BCM determines the battery state of charge is below 50%, or 45 minutes have elapsed, a load shed message is sent over the CAN . This message turns off the audio/navigation system to save the remaining battery charge. Under this condition the FCDIM (without touchscreen controls) displays System Off to Save Battery Turn Ignition Off, or the FDIM (with touchscreen controls) displays SYSTEM OFF TO SAVE BATTERY PLEASE TURN IGNITION OFF OR START ENGINE to notify the driver that battery protection actions are active.

Engine off load shedding occurs when the engine is not running and the ignition is in the ACC, RUN or delayed accessory position. This load shed state clears once the vehicle has been started and the battery state of charge recovers. If the engine off load shed occurs, the audio/navigation system turns off.

When the ignition is in the RUN position and if load shed occurs, the FDIM (with touchscreen controls) or FDIM (with touchscreen controls) displays TURN POWER OFF TO SAVE BATT. The audio/navigation system shuts down after the message center displays the warning.

If a fault occurs with the battery monitoring sensor or circuit(s), the only engine off load shed strategy that is active is a 45 minute timer. After 45 minutes have elapsed, the audio/navigation system turns off. To clear the load shed state, restart the engine.

When the ignition is in the OFF position or the ignition key removed Infotainment extended play can be enabled. When Infotainment extended play is enabled and a load shed message is received over CAN the extended play turns off to save the remaining battery charge. Under this condition FCDIM (without touchscreen controls) or FDIM (with touchscreen controls) displays SYSTEM OFF TO SAVE BATTERY to notify the driver that battery protections are active.

Engine Running Load Shed

When the BCM and/or PCM voltage is low, with the engine running, the BCM sends a message to either minimize or shut down the climate controlled seats, rear defrost, heated mirrors and climate control blower motor to improve system voltage. Under this condition, the FCDIM (without touchscreen controls) or FDIM (with touchscreen controls) displays LOW BATTERY FEATURES TEMPORARILY TURNED OFF to notify the driver that battery protection actions are active during a Load Shed 2 continuous event.

  There are 3 states of engine running load shed:

Battery Charging

When it is required to charge the vehicle battery, connect the positive connection to the battery positive post, and place the charger negative to vehicle ground. Do not connect the negative cable of the charger to the battery negative terminal. Connecting directly to the battery negative post bypasses the battery monitoring sensor not allowing the sensor to detect the charge current. As a result the battery state of charge does not reflect the charging. Look for the body ground cable coming off the battery monitoring sensor and try and connect in this location (typically on the shock tower sheet metal). The placement of the battery is such that the battery negative terminal is located under the sheet metal shroud making sheet metal ground the obvious choice for the charger.

If the battery is being charged due to a load shedding message, only charging the battery properly assists in clearing this message. The Electrical Energy Management recalibrates the battery state of charge as described above after about 8 hours if the charger was improperly installed.

NOTICE: If the charger is incorrectly connected to the battery negative terminal, DO NOT reset the battery monitoring system using the diagnostic scan tool. This reset is reserved only for new battery installation. This reset clears the learned battery data, the battery time in service, and affects the aging algorithm parameters, which have been learned since the installation of the battery.

Jump Starting

When it is required to jump start the vehicle, just like battery charging, it is important to connect the cables properly for the Electrical Energy Management system to measure the energy input to the system to keep an accurate State of Charge. Connect the positive connection to the battery positive post, and connect the Jump Start negative to the vehicle ground. Do not connect to the negative battery terminal. Connecting directly to the battery negative post bypasses the ability of the vehicle to measure the input current with the battery monitoring sensor, and does not adjust the battery state of charge accordingly. For a convenient ground location look for the body ground cable coming off the clamp or the Battery Monitor Sensor and try and connect in this location (typically on the shock tower sheet metal). The Electrical Energy Management recalibrates the battery state of charge as described above after about 8 hours if the jump start negative cable is improperly installed.

NOTICE: If the cables are incorrectly connected to the battery negative terminal, DO NOT reset the battery monitoring system using the diagnostic scan tool. This reset is reserved only for new battery installation. This reset clears the learned battery data, the battery time in service, and affects the aging algorithm parameters, which have been learned since the installation of the battery.

Battery Replacement

If the vehicle battery is replaced, it is very important to perform the battery monitoring system reset using the scan tool. If the battery monitoring system reset is not carried out, it holds the old battery parameters and time in service counter in memory. Additionally it tells the system the battery is in an aged state and the may limit the Electrical Energy Management system functions. For more information,
Refer to: Battery and Cables - System Operation and Component Description (414-01 Battery, Mounting and Cables, Description and Operation).

Component Description

Generator

The generator is driven by the FEAD drive belt. When the engine is started, the generator begins to generate AC voltage which is converted to DC voltage by the internal voltage regulator. The DC voltage is controlled by the voltage regulator and supplied to the battery. The PCM controls the voltage regulator set point, communicating with the generator internal voltage regulator over a dedicated LIN communication circuit. The generator is equipped with a non-serviceable generator clutch pulley.

Battery Monitoring Sensor

The battery monitoring sensor is integrated with the negative battery terminal clamp and cable assembly, which provides a ground to the sensor. The battery monitoring sensor measures voltage, current, and temperature of the battery and uses these inputs to calculate the battery condition. The sensor transmits this information through a LIN circuit to the BCM . The battery monitoring sensor has a 2-pin connector providing battery voltage and LIN connections.

Powertrain Control Module (PCM)

The PCM monitors and controls the charging system.

Generator Clutch

The primary function of the generator clutch is to separate the generator rotor inertia from the FEAD belt, lowering belt tension at high Revolutions Per Minute (RPM) and reducing NVH . The generator clutch cannot be serviced separately from the generator.

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