Balance Hybrid Service Manual -Vehicle Operation & Identification
Contents
1. Ambient Air Maximum Engine Temperature Off Time s C 20 900 25 240 30 180 35 90 40 60 45 30 50 0 The maximum engine off time is scaled linearly between the breakpoints and held constant at the endpoint value for ambient air temperature values outside the breakpoint range W hen the engine is turned on because the maximum off time has been exceeded it remains on for a minimum of 30s for the cab a c strategy before itis allowed to turn off again Over key cycles the last known ambient air temperature and cab a c state are saved by the VCU to avoid having to wait for 20s of engine on time on the next key cycle before the ambient air Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 29 AZD Service Manual temperature can be evaluated At key on if the previous ambient air temperature was greater than 35 C and the cab a c was engaged the engine will be immediately forced on at key start Behavior difference between vehicles with cab a c pressure switch and vehicles with cab a c clutch state sent over CAN In situations where the VCU is not alive before the key is turned on there is a slight difference in response to a cab a c request by the driver via dash switch prior to key on between vehicles that have a cab a c pressure switch and those that have the cab a c clutch state reported over CAN e Cab a c pressure switch When the key is turned on the cab a c request is2. N ra flagged POAOF ehicte forced into EV mode Fi Ba 1 The sequence will begin at either of the yellow rectangles above The start sequence begins at Engage 12V Starter M otor if any of the conditions mentioned in the U se of Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 24 AZD Service Manual 12V Starter section above are satisfied Otherwise the sequence begins at A pply cranking torque with ISG 2 Maximum ISG engagement time 4s 3 Maximum 12V starter engagement time based on ECT as outlined in the table below ECT C Maximum 12V Starter Engagement Time s 40 10 18 45 0 2 5 20 2 50 2 The maximum 12V starter engagement time is scaled linearly between the breakpoints and held constant at the endpoint value for ECT values outside the breakpoint range 3 4 3 Coolant Pump Strategy When the hybrid powertrain is enabled the coolant pump is enabled If the ESS coolant temperature drops below 12 C gt 14 C to reset condition AND the ESS maximum module temperature drops below 18 C gt 20 C to reset condition then the coolant pump is cycled 10s ON 20s OFF to allow the ESS to heat up faster ESS Cooling After K ey Off When HV is disabled either for a key off event or for a transition into conventional mode if the ESS coolant temperature is greater than 30 C and the ESS maximum module temperature is greate
3. gt 51 2 Without body a c enabled a If the vehicleisin P N R or D with vehicle speed lt 5km h high idle will be requested if the SOC lt 39 reset when SOC gt 45 b If the vehicle isin D with vehicle speed gt 5km h high idle will be requested if the SOC lt 45 reset when SOC gt 51 3 4 10C ab A C Strategy In vehicles equipped with cab a c the maximum engine off time is modified to ensure cab temperature is maintained The engagement of the cab a c system is detected by the VCU by 2 different methods depending on the vehicle 1 MY 08 cut aways and stripped chassis the cab a c clutch state is sent to the VCU from the PCM over CAN 2 MY 08 shuttle buses and M Y 09 vehicles a cab a c pressure switch digital input to the V CU indicates the engagement of the cab a c system The intake air temperature reported by the PCM over CAN is used by the VCU as the ambient air temperature However this temperature is only considered valid for the a c strategy after the engine has been on for 20s to ensure air flow through the intake If the cab a c is engaged and the ambient air temperature is greater than or equal to 50 C the engine is kept on until the ambient air temperature falls below 48 C or the cab a c is no longer engaged If the cab a c is engaged and the ambient air temperature is less than 50 C the maximum time that the engine is allowed to be off is based on the ambient air temperature outlined in the table below
4. starter and to charge the high voltage system An energy storage system a battery provides electrical energy storage The primary energy saving mechanisms used by the hybrid are engine idle off strategy and regenerative braking Atlow speeds when the engine is not required for drive demand or ESS charging the engine will be shutdown W hen required the engine will be re started quickly usually by the FEAD ISG When the engine is shutdown the DC DC converter and electric power assist system will be enabled to provide the 12 volt charge and power steering and brakes W hen the engine is running these functions are provided by the FEAD power assist pump and alternator Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 18 AZD Service Manual E MPT Motor Inverter FEAD Starter Generator Transmission Balance Hybrid System Schematic In typical hybrid mode operation the vehicle will accelerate at low speeds with the engine off electric only mode The engine will be started by the ISG and the M PT will continue to assist the engine until itis up to speed At that point the engine will provide most of the propulsion power except during transient acceleration conditions where the M PT will assist In the case of low SOC the ISG will charge the ESS by absorbing power from the engine During braking the MPT motor will act as a generator slowing the rear wheels and charging the ba
5. AZD Service Manual 3 Vehicle Operation amp Identification 3 1 Basic Theory of Operation s sssssssssunnnsunnnnnnnnunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnananannnnnnnnannnnnnanananan 18 3 2 Safety Feat reSisssoiiiaisanaiarsiaii annaa aaaniani dadaanan aaniu ananafi iadaa i iradia padaan 21 Bid MOUS OF Operation eis casatcssncvactecsecateiensdentisracitersnsarcerstaitiinadestciiendnienuntuiaen 21 ZA Operating Strate hes sisicisisissstssssssstssssssscssnssssasessosassescnsssnssssassassasssrsssescssarsestessssnaasanns 22 3 5 lgnition Starter Switch sescissssssisssnscssessnsissrsnsescesssstscsncesascescssnissssesssstencerciresneccsrenssanie 31 3 6 Standard Hybrid Indicators u ssi 32 3 7 Optional Hybrid Switches s sssssssssnnnusnsuonnnnnunnnnnnnnnnnnnnnnnnnunnnnnnnnunnnnonananunnnnnnnnnnnnnanananan 33 3 8 Automatic Transmission Operation 34 3 9 Speed Limits for Specific Vehicle C onfigurations sssee ee 35 3 10 Hybrid Identification siscistwsisccsiceidecstssescccutsctssctesancssinentersiterestasterentantnntainiedeemsinanenat 35 3 1 Basic Theory of Operation The Balance Hybrid is a parallel hybrid vehicle A parallel hybrid can use one or more motive sources in combination for vehicle acceleration The Balance hybrid has a gasoline engine along with a large electric motor to provide propulsion force A second smaller motor Integrated Starter G enerator ISG is attached to the engine s FEA D system its purpose is to serve as an engine
6. While in electric only mode if the ESS is sufficiently discharged the engine will be forced back on to charge the ESS Whenever the vehicle is re started the default mode is Hybrid 3 8 Automatic Transmission Operation The brake shift interlock and gear selection functions are the same as on a non hybrid Ford E 450 Refer to the Ford E 450 Owner s Guide for more information W hen leaving the vehicle Always set the parking brake fully and make sure the gearshift is latched in P Park Turn the ignition to the LOCK position and remove the key whenever you leave your vehicle 3 8 1 Vehicle Creep Asin a non hybrid the hybrid vehicle is designed to creep forward when in gear if the brake pedal is released and the throttle pedal is not pressed Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 34 AZD Service Manual 3 9 Speed Limits for Specific Vehicle Configurations For step vans and cut a ways the vehicle speed limit is 65mph 105km h For shuttle buses the vehicle speed limit is 7Omph 112 km h 3 10 Hybrid Identification The vehicle can be identified as a hybrid by the following features e The presence of hybrid components installed on the vehicle Hybrid W arning Labels under the hood e Orange colored cables and looming that are used for high voltage They are visible under the vehicle e HYBRID ENABLED and HY BRID SERVICE indicator lights on the dash e Customer specific Hyb
7. an PWM setup 90 gt 50 duty cycle 3 4 9 Engine High Idle Strategy T1 V lt 12 4 debounced for 30 s OR V lt 12 0 debounced for 8 s OR V lt 11 5 debounced for 5 s AND Powertrain state is enabled T2 V lt 12 4 debounced for 7 s during current state T3 40 s during current state AND T2 not true T4 40 s during current state AND T5 not true T5 V lt 12 4 debounced for 15 s during current state T6 V gt 12 4 debounced for 30 s during current state Notes V refers to 12 volt battery voltage read at vehicle ignition In conventional mode the Engine On state is bypassed in both directions because the engine is already on Also in conventional mode the step Load Shed is skipped in both directions as body AC system is disabled in conventional mode anyways and hence this state becomes identical to the High Idle state High idle will be requested of the engine for the 12V battery management see 12V Battery Management Strategy It will also be requested for low SOC based on the following conditions 1 With body a c enabled a If the vehicle isin P N R or D with vehicle speed lt 5km h high idle will be requested if the SOC lt 44 reset when SOC gt 47 Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 28 AZD Service Manual b If the vehicle is in D with vehicle speed gt 5km h high idle will be requested if the SOC lt 49 reset when SOC
8. and the PCM has been jeopardized or the PCM feedback is flagging critical errors the vehicle will enter conventional limp home mode This is the same as conventional mode except the VCU will request zero torque in this condition and the engine will operate in idle mode Forced EV mode In the case that vehicle cannot start the engine the vehicle will drive in EV mode As the ESS SOC reduces the drive power available will also reduce The power assist will remain available until the ESS is forced to open contactors The HY BRID SERVICE will be blinking see section 3 5 3 4 Operating Strategies 3 4 1 Arctic M ode Strategy Cold E PAS Inverter Application of EPAS 12V ignition power J 6 1 via the Arctic M ode relay VCU C310S H1 at temperatures below 20 C can result in damage to the EPAS inverter therefore at cold ambient temperatures the Arctic M ode relay must be deactivated to disable the EPAS inverter and the engine must be forced on to provide power assist The Arctic mode strategy works as follows 1 Atkey off the VCU power is latched for the time it would take the EPAS inverter to cool from its current temperature to 15 C This allows the VCU to make immediate decisions based on EPAS inverter temperature if the ignition key is turned back on during the power latch time period without having to enable the engine to assess ambient air temperature The time that the VCU power is latched is based on EPAS inverter te
9. e engine is forced on until the inverter temperature increases as described in point 1 Cold TM Inverter TheTM Inverter is not able to operate at ambient temperatures below 20C requiring the vehicle to be forced into conventional mode The cold TM inverter strategy works as follows 1 If directly before key on the VCU is NOT alive the TM inverter is disabled via the E M PS Enable relay VCU C308S H3 and the vehicle is forced into conventional mode If the TM inverter temperature is above 10 C the E M PS Enable relay is enabled to permit TM inverter operation and the vehicle transitions into hybrid mode Otherwise the TM inverter remains disabled and the vehicle remains in conventional mode Once the TM inverter is enabled and the vehicle transitions to hybrid mode if the reported inverter temperature falls below 15 C the TM inverter is disabled and the vehicle is forced into conventional mode again If directly before key on the VCU is alive if the TM inverter was previously warm enough to be enabled and the vehicle was in hybrid mode the TM inverter is immediately enabled and the vehicle starts in hybrid mode Otherwise the TM inverter is disabled and the vehicle starts in conventional mode until the inverter temperature increases as described in point 1 Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 23 AZD Service Manual 3 4 2 Engine Start Up Strategy Use of the 12V Starter M otor The engine wil
10. e maximum off time has been exceeded it remains on for a minimum of 30s for the cab heater strategy before it is allowed to turn off again N ote that the engine is also turned on based on engine coolant temperature and ambient air temperature for the engine warm up strategy as listed in the Engine Start Source and Engine On Source sections Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 30 AZD Service Manual 3 5 Ignition Starter Switch The ignition starter switch functions in the same manner as in a non hybrid Ford E 450 except for the starting operation described below Refer to the Ford E 450 Owner s Guide for more information 3 5 1 Starting the Vehicle 1 Ensure the gearshift is in P Park 2 Turn the key to 4 ON without turning the key to 5 START All electrical circuits will be operational warning lights will be illuminated eve aM LED wa the vehicle All electrical circuits een gt ae and warning een illuminated Green eve aM LED wa ENABLED light wil be illuminated Ay Figure 4 Ignition starter switch position Turn the key to 5 START momentarily and hold for about 1 second and release The Green HYBRID ENABLED light on the dash will illuminate which indicates that the vehicle is ready to drive even if the engine is not running Whenever the Green HY BRID ENABLED light is illuminated the vehicle is ON and ready to drive even if the engine is not run
11. l be cranked with the ISG unless any one or more of the conditions listed below are active 12V Starter Source Condition Conventional M ode The vehicle is in Conventional mode ISG Inhibit 1 An ISG related diagnostic trouble code has been flagged by the VCU OR 2 ThelSG is not ready for operation slow boot up on key start Low ECT ECT lt 10 C ESS Power Limit ESS discharge power limit lt 9500kW ISG Torque Limit ISG available torque limit lt 80Nm NOTE The 12V starter source is displayed on the Balance Diagnostic Tool Cranking Sequence J NO YES A N Engine Generate Abi paer Kiehicle forced into EV speed gt NO gt Performance gt lt rent crank TES mode J 125rpm DTC flagged Nv Seen ig P0A92 Ra 7 k NO YES YES YES First ISG Engine J Aor 2nd crank NO fired attempt Engine Starter SG used firs 12V starter Performance speed gt NO Sno in current 125rpm crank DTC flagged rank attemp mpm attempt P1A31 ii YES Engine Failed k to Start DTC Zones ZO N flagged YES Eon 29 12 EA POAOF lt starter crank gt N0 _ Engine fired gt YES attempt Se we wo ba Na YES yA fo fons N R i i R vehicle forced into Ev r ISG crank Engine Failed Successful 12V starter Vehicle forced into EV A mode fa oN J to Start DTC crank J mode jJ SS
12. lectric shut off inertia switch Automatically disables the high voltage electrical system W henever the high voltage service disconnect pin is removed the high voltage system will be disabled It is located at the front end of the battery pack The battery pack contains a fuse that will open in the event of a short circuit If the vehicle s ignition key is on and the high voltage battery temperature exceeds 75 C 167 F the thermal sensors will disconnect the high voltage battery The VCU and ESS continually monitor the potential resistance between the high voltage system and the chassis If the resistance falls below an acceptable threshold the VCU ESS will open the contactors in the ESS and the vehicle will be forced into a Conventional Mode The HYBRID SERVICE lamp will be illuminated Vehicle Brake Lamp Operation During Regenerative B raking Events The vehicle brake lamps will be illuminated during regenerative braking events if the requested regenerative braking torque exceeds 150N m 3 3 Modes of Operation Operation M odes There are several different modes that the vehicle will operate in depending on driver technician request or fault conditions being present The table below details these modes Mode Description H ybrid Normal hybrid functionality EV Electric only mode Vehicle will operate in EV mode in low power speed conditions It is also driver selectable in vehicles which include the o
13. mperature as outlined in the table below EPAS VCU Power Latch Inverter Time s Temperature C 5 5 4 600 0 600 Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 22 AZD Service Manual 19 600 20 1200 The VCU power latch time is scaled linearly between the breakpoints and held constant at the endpoint value for EPAS inverter temperature values outside the breakpoint range 2 If directly before key on the VCU is NOT alive the EPAS inverter is disabled via the Arctic M ode relay and the engine is forced on Once the engine has been on for 30s the PCM reported IAT is evaluated to determine the ambient temperature If the PCM reported IA T temperature is above 10 C and the TM inverter temperature is above 10 C the Arctic M ode relay is enabled permitting EPA S operation and the engine is allowed to turn off Otherwise the EPA S inverter remains disabled and the engine remains on Once the EPAS inverter is enabled if the reported inverter temperature falls below 15 C the EPA S inverter is disabled via the Arctic M ode Relay and the engine is forced on again If directly before key on the VCU is alive if the EPAS inverter was previously warm enough to be enabled and to allow the engine to turn off the Arctic M ode relay is immediately re enabled to allow EPAS operation and the engine can remain off Otherwise the Arctic M ode relay is disabled and th
14. namics Balance Hybrid electric Vehicle 2008 Ford E 450 26 AZD Service Manual In conventional mode the radiator fan DC will only be greater than 0 if the engine is enabled and the engine coolant temperature conditions are met The radiator fan DC will not be controlled by ESS coolant temperature conditions The VCU does not disable the radiator fans at high vehicle speeds Additionally if the 12V battery management state is in Critical Load Shed see 12V Battery M anagement Strategy radiator fan DC shall be derated to a maximum of 50 3 4 5 IDS Tool Connection In order to perform engine diagnostics the IDS tool can be connected to the PCM at any time 3 4 6 Body A C Strategy On vehicles equipped with body A C the body A C shall be enabled if all of the following conditions are met 1 2 3 4 5 Body A C clutch is engaged HV is enabled 12V battery voltage state is NOT Load Shed or Critical Load Shed see 12V Battery M anagement Strategy ISG is not faulty SOC gt 41 The speed setpoint of the body A C is based on the SOC as outlined in the table below ESSSOC_ Body A C Speed Setpoint rpm 39 1600 43 3000 75 3000 80 5000 The body A C speed setpoint is scaled linearly between the breakpoints and held constant at the endpoint value for SOC values outside the breakpoint range 3 4 7 TM Power Derating based on SOC The maximum TM motor acceleration power limit i
15. ning W hen the key is in the ON position HY BRID ENABLED light is ON the engine may start or stop without warning Remove the key from the ignition when working on the vehicle or under the hood The vehicle should not be left unattended with the key in the RUN position 3 5 2 How to Turn the Hybrid OFF 1 Come to a complete stop Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 31 AZD Service Manual 2 Engage the parking brake 3 Place the gear selector in P Park 4 Turn the key to the OFF position 3 6 Standard Hybrid Indicators There are two lights on the driver s console located to the right of the steering column a Green HYBRID ENABLED light and a Y ellow HY BRID SERVICE light refer to illustration The function of these lights is described in the table that follows 7 Hybrid Not Ready to Drive Ensure key has been turned to START position Figure 5 Hybrid Indicators I FLASHING Limp Home P Ss Figure 6 Hybrid Controls and Indicators Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 32 AZD Service Manual 3 6 1 HYBRID ENABLED The green light emitting diode LED lights when the vehicle is ready to drive If the technician has commanded Conventional M ode by removing the jumper connector C163S which is located under the dash the light will remain OFF while the vehicle is running 3 6 2 HYBRID SERVICE If any problem is detected in
16. ptional EV MODE switch Conventional Hybrid functionality disabled for service purposes vehicle drives as a regular conventional vehicle This is selectable by the technician by removing the conventional mode connector C163 located under the Dash Note that this mode is not a true conventional mode The vehicle will Operate in amanner similar to a conventional vehicle no engine off operation high voltage will not be enabled etc but the VCU still controls much of the functionality of the vehicle This mode should only be used for certain diagnostic procedures Leaving the vehicle in this mode will have Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 21 AZD Service Manual negative effects on the fuel economy and performance of the vehicle The connector should always be reconnected at the end of the diagnostic procedure Forced Conventional Due to a hybrid fault the vehicle is forced to operate in conventional mode The vehicle will remain in conventional mode until key off At the next key on event the VCU will re evaluate the fault conditions to determine if conventional mode is still required Diagnostics Diagnostics mode is selectable through the diagnostics tool It allows for control of various VCU outputs and vehicle functions for purposes of vehicle commissioning and diagnostics Conventional Limp Home Due to a severe fault where the communication between the VCU
17. r than 35 C then the coolant pump will be enabled for 2 minutes after HV is disabled E ngine Derating for Overheating Maximum available engine torque is derated based on ECT as outlined in the table below ECT C M aximum E ngine Torque Nm 105 510 110 270 118 145 122 90 The maximum engine torque is scaled linearly between the breakpoints and held constant at the endpoint value for ECT values outside the breakpoint range Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 25 AZD 3 4 4 Radiator Fan Strategy Triple Radiator Fans MY09 and MY08 Production Level Vehicles All three radiator fans shall be enabled if cab a c is enabled The component temperature thresholds for enabling the radiator fans are outlined in the table below Service Manual Component 1 Fan Temperature 2 Fan Temperature 3 Fan Temperature Threshold C Threshold C Threshold C ESS coolant With EngineON With EngineON With EngineON temp gt 25 reset lt 20 n a gt 35 reset lt 30 With Engine OFF With E ngine OFF With Engine OFF gt 35 reset lt 30 n a gt 45 reset lt 40 Engine coolant temp gt 90 reset lt 85 gt 98 reset lt 93 gt 103 reset lt 98 NOTES 1 In hybrid mode the radiator fans will only be enabled if the hybrid powertrain is enabled Additionally the engine coolant temperature conditions will only be u
18. recognized by the VCU and the engine is forced on after it has been off for the maximum off time listed above e Cab a c clutch state reported over CAN When the key is turned on the cab a c request will NOT be recognized by the VCU initially hence the engine will remain off regardless of the driver s a c request until the engine has been enabled for some other reason 3 4 11C ab H eater Strategy The maximum engine off time is modified to ensure cab heat is maintained in cold ambient temperatures Similar to the cab A C strategy the intake air temperature reported by the PCM over CAN is used by the VCU as the ambient air temperature However this temperature is only considered valid for the cab heater strategy after the engine has been on for 20s to ensure air flow through the intake If the ambient air temperature is less than or equal to 30 C the engine is kept on until the ambient air temperature rises above 28 C If the ambient air temperature is greater than 30 C the maximum time that the engine is allowed to be off is based on the ambient air temperature outlined in the table below Ambient Air Maximum Engine Temperature Off Time s C 30 0 20 30 10 240 0 300 10 900 The maximum engine off time is scaled linearly between the breakpoints and held constant at the endpoint value for ambient air temperature values outside the breakpoint range When the engine is turned on because th
19. rid labeling on the vehicle Note these labels may or may not be present these are customer controlled 3 10 1H igh Voltage C ables High voltage cables are identified by highly visible orange looming or orange stripes The presence of orange high voltage cables under the hood and under the vehicle identifies the vehicle as a hybrid Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 35
20. s derated based on SOC as outlined in the table below The ESS SOC should only reach such critically low levels when the vehicle is in Forced EV mode Once 20 has been reached or the vehicle has been in Forced EV mode for 5 minutes traction power will be disabled however HV and EPAS will remain enabled ESS SOC Maximum TM Acceleration Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 27 AZD Power Limit kW 20 0 30 60 35 80 Service Manual The maximum acceleration power limit is scaled linearly between the breakpoints and held constant at the endpoint value for SOC values outside the breakpoint range 3 4 8 12V Battery M anagement Strategy 12V Battery Management Strategy Normal No engine on request Engine On Je Request engine on No high idle request T2 T4 High Idle Request engine on Request high idle No charge lamp request Body AC system request passed through T5AND HybridMode T6 Load Shed Request engine on Request high idle Enable charge lamp Disable body AC system Iv and hv Rad fans request passed through VCU flags fault latched for the cycle T5 AND Conventional M ode T6 AND Conventional M ode T5 i Critical Load Shea T6AND Hybrid M ode Request engine on Request high idle Enable charge lamp Body AC disabled Iv and hv Rad fans request modified Triple fan setup 3 fans gt single f
21. sed to enable the radiator fans if the engine is enabled 2 In conventional mode the radiator fans will only be enabled if the engine is enabled and the engine coolant temperature conditions are met The radiator fans will not be enabled for ESS coolant temperature conditions 3 TheVCU does not disable the radiator fans at high vehicle speeds 4 Additionally if the 12V battery management state is in Critical Load Shed see 12V Battery M anagement Strategy only the single radiator fan shall be allowed to be enabled should the conditions described above be met The dual radiator fans shall be disabled Single PWM Radiator Fan MY08 Pre Production Level Vehicles The radiator duty cycle DC shall be set to 100 if the cab a c is enabled The component temperature thresholds controlling the radiator fan DC are outlined in the table below with the DC being scaled linearly between the 0 and 100 component temperatures Component 0 DC Temperature Threshold C 100 DC Temperature Threshold C ESS coolant temp With EngineON 30 With Engine OFF 35 With E ngine ON 35 With E ngine OFF 40 Engine coolant temp 95 103 xNOTES 1 In hybrid mode the radiator fan DC will only be greater than 0 if the hybrid powertrain is enabled Additionally the engine coolant temperature conditions will only be used to command a radiator fan DC greater than 0 if the engine is enabled Azure Dy
22. the hybrid system the yellow LED will light or flash depending on the type of fault If the HY BRID SERVICE lightis ON or was ON during a drive cycle the vehicle should be taken to the garage for service 3 6 3 Limp Home Mode Certain failures of vehicle systems both conventional and hybrid will not allow the vehicle to operate as normal The vehicle will have reduced performance levels This limited operation allows the driver to pull over safely to the side of the road and call for service The vehicle should not be run for extended periods of time in Limp Home M ode 3 7 Optional Hybrid Switches Depending on the application the RBS OFF optional switch may be present on the vehicle 3 7 1 RBS OFF Optional on Shuttle Bus Only W hen this switch is pressed the Regenerative Braking System RBS will be turned off and the LED in the switch will illuminate To re enable regenerative braking press the switch again and the light will shut off Note Whenever the vehicle is re started the default mode is to always have RBS on Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 33 AZD Service Manual 3 7 2 Electric Vehicle optional When this switch is pressed the light will illuminate and the vehicle will switch from hybrid mode into electric only mode no engine start at a reduced acceleration rate and reduced maximum vehicle speed To re enable hybrid mode press the EV switch again and the light will shut off
23. ttery pack the vehicle brake lamps will be illuminated during regenerative braking events if the requested regenerative braking torque exceeds 150Nm At lower speeds the engine will shut down again The graph below illustrates typical hybrid operation during a drive cycle Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 19 AZD Service Manual engine provides drive power plus MPT motor assist engine provides drive power plus ISG battery chargin on regenerative braking MPT battery engine provides acceleration torque charging Vehicle Speed gt engine engine ramps up shutdown MPT assist engine startup electric drive MPT electric drive Time gt Typical Hybrid System Operation Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 20 AZD Service Manual 3 2 Safety Features The following list indicates some of the safeguards incorporated in the design of the hybrid vehicle to disconnect the high voltage and to ensure that the vehicle is kept safe at all times 1 2 The high voltage system is disconnected when the vehicle s ignition key is turned to the OFF position There are 2 inertia switches on the hybrid vehicle that may be activated in the case of an accident e Thelnertia Fuel Shut off IFS switch Ford standard equipment that automatically disables the engine s fuel pump e The hybrid e
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