Lincoln Aviator: High Voltage Battery, Mounting and Cables / Description and Operation - High Voltage Battery, Mounting and Cables - Plug-In Hybrid Electric Vehicle (PHEV) - Overview

OVERVIEW

  WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage system utilizes approximately 450 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death.

NOTICE: The high voltage battery in a PHEV can be affected and damaged by excessively high temperatures. The temperature in some body shop paint booths can exceed 60°C (140°F). Therefore, during refinishing operations, the paint booth temperature must be set at or below 60°C (140°F) with a bake time of 45 minutes or less. Temperatures exceeding 60°C (140°F) or bake durations longer than 45 minutes require the high voltage battery be removed from the vehicle prior to placing in the paint booth.

The plug in hybrid can be used as an electric vehicle, conventional hybrid vehicle, or both. The high voltage battery on the plug in hybrid application has more capacity than a full hybrid application and can be fully charged using EVSE (Electric Vehicle Supply Equipment) connected to the vehicle charge port. A drive mode dial located on the center console is used to change the vehicle operating strategy.

The vehicle can be placed in electric mode only (Pure EV Mode) allowing only the electric motor to propel the vehicle. In this mode the high voltage battery depletes and the gas engine does not operate unless a calibratable condition exists such as a malfunction, heavy acceleration, high electric motor temperature, elevated high voltage battery temperature, low high voltage battery state of charge, or certain climate control functions are selected (e.g. defrost).

The vehicle also operates as a conventional hybrid (Preserve EV Mode) and utilize both the electric motor and the gasoline engine to propel the vehicle. In this mode the high voltage battery state of charge is sustained (not depleted or charged). When the vehicle is operating in charge (Preserve EV Mode) the electric motor supports the gas engine during moderate to heavy acceleration and uphill driving. In low-speed driving situations the vehicle moves under only battery power and without the internal combustion engine running. The internal combustion engine automatically shuts off when the vehicle is stopped/idling or when coasting. If certain conditions are met the engine restarts when the accelerator is pressed to provide assistance to the electric motor or when the high voltage battery state of charge is low. This avoids using excess fuel when the vehicle is not in motion.

When the vehicle is placed in (Normal Mode) the vehicle automatically controls usage of the high voltage battery and switches between maintaining, depleting, and charging of the High Voltage Battery to maximize vehicle performance and fuel economy based on vehicle operating conditions.

Regenerative braking is utilized in all modes of operation which transforms the energy that is normally wasted during stop and go operation (when coasting and braking) into electricity. The generated electricity is stored in the high voltage battery until it is needed by the electric motor or the 12-volt system.

The vehicle does not require to be plugged into an external source of electricity. The energy provided by the engine and the regenerative braking, via the electric motor used as a generator motor, sustains the high voltage battery state of charge.

The high voltage battery pack consists of the following serviceable components:

• BECM
• High voltage battery upper cover seal
• High voltage battery lower seal
• High voltage battery junction box
• High voltage high current fuse (mounted in the high voltage battery junction box)
• High voltage low current fuse (mounted in the high voltage battery junction box and supplies voltage to the DCDC and SOBDM also known as the BCCM (Battery Charger Control Module
• High voltage low current fuse (mounted in the high voltage battery junction box and supplies voltage to the Cabin Coolant Heater and ACCM
• Wiring harness (BECM to vehicle low voltage connector)
• Low voltage connector header
• High Voltage connector header
• Coolant port assembly
• Vent patch

All of the high voltage battery components listed above can be serviced separately. All other components are serviced as part of the high voltage battery pack and should not be removed. If the high voltage battery pack is replaced it includes all of the components in the list.

The high-voltage system consists of the following components:

• High-voltage battery cable
• High-voltage ACCM cable
• Electric motor 3 phase AC cable
• Inverter System Controller (ISC) also known as the SOBDMC
• Electric motor assembly (mounted to the front of the transmission)
• DCDC
• Battery Charger Control Module (BCCM) also known as the SOBDM
• Cabin Coolant Heater
• ACCM and A/C compressor assembly located on the lower LH side of the engine block
• High-voltage battery pack