Ford Electric Ranger 2001 Manual page 607

414-03B-4
DESCRIPTION AND OPERATION
High Voltage/Traction Battery
The traction battery is the primary source of power
for the Ranger EV. It is located between the frame
rails and underneath the vehicle. The supporting tray
contains all of the traction battery components. The
tray is made of a strong, non-conductive composite
material and has brackets molded into it at various
locations. The traction battery, when fully loaded
with all necessary components, weighs 595 kg
(1,310 lb). The NiMH traction battery components
are not interchangeable with the lead acid traction
battery components. The NiMH traction battery is
identified by its green label.
The traction battery contains 25 nickel metal
hydride battery modules, a battery controller module
(BCM), the independent observer module (IOM ), a
contactor box, a cooling system, and all necessary
wiring. The 25 battery modules are wired together
in series in order to achieve the necessary 300 volts
(nominal) of direct current (DC) required for vehicle
operation. The BCM and the IOM are located in the
front end of the pack. The contactor box is in the
rear end of the pack. The cooling system uses two
blowers to circulate fresh, cool air through the
battery pack. The flow through blower, which is
mounted in the front of the battery pack, brings
fresh air into the pack. The recirculating blower is
located in the center of the battery pack and
circulates air throughout the battery pack.
The traction battery uses a combination of high and
low-voltage wiring. The high-voltage wiring is
identified by its orange color or orange wrapping.
The high-voltage circuit is protected by a 500 volt,
250 amp fuse. The low-voltage harness serves as
an interface with the rest of the vehicle. This
harness connects the vehicle through the 76-pin
connector, located on the LH front of the traction
battery.
Contactor Box
The contactor box contains relays that switch the
high-voltage on and off. The relays shut off
high-voltage when the ignition key is in the OFF
position, when the vehicle is being charged, 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 charger, and high-voltage auxiliary
circuits.
High Voltage/Traction Battery — Nickel Metal Hydride
Battery Controller Module (BCM)
The BCM is a combination low and high-voltage
module that controls all traction battery system
operations. The BCM monitors selected battery
module temperatures, state of charge for the 25
battery modules, and controls traction battery
charging and cooling. The module also calculates
the maximum source and sink currents to ensure
safe and reliable pack performance.
High Voltage Power Distribution Box (HVPDB)
The HVPDB is located on top of the traction battery
charger in the underhood compartment. The
HVPDB distributes high-voltage to the DC/DC
converter, vehicle heating system, air conditioning
system, power steering system, and the traction
battery charger. The box contains fuses to protect
the circuits to which the high-voltage is supplied.
The box uses a protective cover that is part of the
interlock circuit. When the cover is removed, a limit
switch will open the relays in the contactor box to
interrupt high-voltage to the vehicle.
Independent Observer Module (IOM)
The IOM is a module that monitors the traction
battery temperature during charging using its own
independent thermistors. In the event that the IOM
detects a battery pack over-temperature condition, it
will interrupt the pilot signal to the BCM. This
event will cause an interruption of vehicle charging.
Pilot signal from the PCS of the IOM is as follows:
• When the vehicle is plugged into the power
control station PCS, a squarewave pilot signal is
sent through the charge cord to the IOM via the
charge inlet.
• If the IOM determines that the battery temperature
is within normal charging parameters, it allows
the pilot signal to pass to the onboard battery
charger and then to the BCM.
• The BCM receives the signal from the charge
inlet door switch notifying it that the vehicle has
been plugged in.
• Once the BCM receives the plugged in signal
from the charge inlet door switch, it sends fault
detection signals to the IOM to determine if there
are any faults.
414-03B-4
2001 Ranger EV, 01/2001