Charging System: Description and Operation

CHARGING SYSTEM
The charging system consists of:
- Generator
- Electronic Voltage Regulator (EVR) circuitry within the Powertrain Control Module (PCM)
- Ignition switch (refer to the Ignition System for information)
- Battery (refer to the Battery for information)
- Battery temperature sensor
- Voltmeter (refer to the Instrument Cluster for information)
- Wiring harness and connections (refer to the Wiring for information)

The charging system is turned ON and OFF with the ignition switch. The system is ON when the engine is running and the ASD relay is energized. When the ASD relay is ON, voltage is supplied to the ASD relay sense circuit at the PCM. This voltage is connected through the PCM and supplied to one of the generator field terminals (Gen. Source +) at the back of the generator.

The amount of DC current produced by the generator is controlled by the EVR (field control) circuitry contained within the PCM. This circuitry is connected in series with the second rotor field terminal and ground.

A battery temperature sensor is used to sense battery temperature. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. This is done by cycling the ground path to control the strength of the rotor magnetic field. The PCM then compensates and regulates generator current output accordingly.

All vehicles are equipped with On-Board Diagnostics (OBD). All OBD-sensed systems, including EVR (field control) circuitry, are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for certain failures it detects. Refer to On-Board Diagnostics in the Electronic Control Modules for more DTC information.

The Check Gauges Lamp (if equipped) monitors: charging system voltage, engine coolant temperature and engine oil pressure. If an extreme condition is indicated, the lamp will be illuminated. This is done as reminder to check the three gauges. The signal to activate the lamp is sent via the PCI bus circuits. The lamp is located on the instrument panel. Refer to the Instrument Cluster for additional information.

BATTERY TEMPERATURE SENSOR
The PCM incorporates a Battery Temperature Sensor (BTS) on its circuit board.

The PCM uses the temperature of the battery area to control the charge rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases.

The function of the battery temperature sensor (BTS) is to enable control of the generator output based upon ambient temperature. As temperature increases, the charging rate should decrease. As temperature decreases, the charging rate should increase. The sensor functions similar to the ECT sensor with one major difference, the ambient sensor does not have a dual temperature range program. The PCM maintains the maximum output of the generator by monitoring battery voltage and controlling battery voltage to a range of 13.5 - 14.7 volts.

The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20 °F.

GENERATOR
The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. The generator produces DC voltage.

As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor.

The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicles electrical system through the generator, battery, and ground terminals.

Noise emitting from the generator may be caused by:
- Worn, loose or defective bearings
- Loose or defective drive pulley
- Incorrect, worn, damaged or misadjusted drive belt
- Loose mounting bolts
- Misaligned drive pulley
- Defective stator or diode
- Damaged internal fins

VOLTAGE REGULATOR
The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced.

The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground.

Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage (B+) and battery temperature or inlet air temperature sensor (refer to Battery Temperature Sensor or Inlet Air Temperature Sensor for more information). It then determines a target charging voltage. If sensed battery voltage is 0.5 volts or lower than the target voltage, the PCM grounds the field winding until sensed battery voltage is 0.5 volts above target voltage. A circuit in the PCM cycles the ground side of the generator field up to 100 times per second (100Hz), but has the capability to ground the field control wire 100% of the time (full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 25% is used by the PCM in order to have some generator output. Also refer to Charging System Operation for additional information.