Charging System Description and Operation w/RVC

The electrical power management (EPM) system is designed to monitor and control the charging system and send diagnostic messages to alert the driver of possible problems with the battery and generator. This EPM system primarily utilizes existing on-board computer capability to maximize the effectiveness of the generator, to manage the load, improve battery state-of-charge (SOC) and life, and minimize the system's impact on fuel economy. The EPM system performs 3 functions:

The battery's condition is estimated during key-off and during key-on. During key-off the SOC of the battery is determined by measuring the open-circuit voltage. The SOC is a function of the acid concentration and the internal resistance of the battery, and is estimated by reading the battery open circuit voltage when the battery has been at rest for several hours.

The SOC can be used as a diagnostic tool to tell the customer or the dealer the condition of the battery. Throughout key-on, the algorithm continuously estimates SOC based on adjusted net amp hours, battery capacity, initial SOC, and temperature.

While running, the battery's degree of discharge is primarily determined by a battery current sensor, which is integrated to obtain net amp hours.

In addition, the EPM function is designed to perform regulated voltage control (RVC) to improve battery SOC, battery life, and fuel economy. This is accomplished by using knowledge of the battery's SOC and temperature to set the charging voltage to an optimum battery voltage level for recharging without detriment to battery life.

The Charging System Description and Operation is divided into 3 sections. The first section describes the charging system components and their integration into the electrical power management (EPM). The second section describes charging system operation. The third section describes the instrument panel cluster (IPC) operation of the charge indicator, driver information center (DIC) messages, and voltmeter operation.

Generator

The generator is a serviceable component. If there is a diagnosed failure of the generator it must be replaced as an assembly. The engine drive belt drives the generator. When the rotor is spun it induces an alternating current (AC) into the stator windings. The AC voltage is then sent through a series of diodes for rectification. The rectified voltage has been converted into a direct current (DC) for use by the vehicles electrical system to maintain electrical loads and the battery charge. The voltage regulator integral to the generator controls the output of the generator. It is not serviceable. The voltage regulator controls the amount of current provided to the rotor. If the generator has field control circuit failure, the generator defaults to an output voltage of 13.8 volts.

Body Control Module (BCM)

The body control module (BCM) is a GM LAN device. It communicates with the engine control module (ECM) and the instrument panel cluster (IPC) for electrical power management (EPM) operation. The BCM determines the output of the generator and sends the information to the ECM for control of the generator field control circuit. It monitors the generator field duty cycle signal circuit information sent from the ECM for control of the generator. It monitors a battery current sensor, the battery positive voltage circuit, and estimated battery temperature to determine battery state-of-charge (SOC). The BCM performs idle boost and load management operations.

Battery Current Sensor

The battery current sensor is a serviceable component that is connected to the negative battery cable at the battery. The battery current sensor is a 3-wire hall effect current sensor. The battery current sensor monitors the battery current. It directly inputs to the BCM. It creates a 5-volt pulse width modulation (PWM) signal of 128 Hz with a duty cycle of 0-100 percent. Normal duty cycle is between 5-95 percent. Between 0-5 percent and 95-100 percent are for diagnostic purposes.

Engine Control Module (ECM)

The ECM directly controls the generator field control circuit input to the generator. It monitors the generators generator field duty cycle signal circuit and sends the information to the BCM. The ECM will override the BCM control of the generator when one of the following conditions are met:

Instrument Panel Cluster (IPC)

The IPC provides a means of customer notification in case of a failure and a voltmeter. There are 2 means of notification, a charge indicator and a driver information center (DIC) message of SERVICE CHARGING SYSTEM and CHARGING SYSTEM FAULT.

The purpose of the charging system is to maintain the battery charge and vehicle loads. There are 6 modes of operation and they include:

The engine control module (ECM) controls the generator through the generator L-terminal control circuit. The signal is a 5-volt pulse width modulation (PWM) signal of 128 Hz with a duty cycle of 0-100 percent. Normal duty cycle is between 5-95 percent. Between 0-5 percent and 95-100 percent are for diagnostic purposes. The following table shows the commanded duty cycle and output voltage of the generator:

The generator provides a feedback signal of the generator voltage output through the generator field duty cycle signal circuit to the ECM. This information is sent to the body control module (BCM). The signal is a 12-volt PWM signal of 128 Hz with a duty cycle of 0-100 percent. Normal duty cycle is between 5-99 percent. Between 0-5 percent and 100 percent are for diagnostic purposes.

Charge Mode

The BCM will enter Charge Mode when ever one of the following conditions are met:

Once one of these conditions are met, the generator battery control module will set the targeted generator output voltage to 13.4 volts and then ramp that voltage up to 14.5 volts at a rate of 50 mV per second.

Fuel Economy Mode

The BCM will enter Fuel Economy Mode when the calculated ambient air temperature is above 0°C (32°F), the calculated battery current is less than 15 amps and greater than -8 amps, and the battery state-of-charge (SOC) is greater than 80 percent. Its targeted generator output voltage is 13 volts. The BCM will exit this mode once the criteria are met for Charge Mode.

Voltage Reduction Mode

The BCM will enter Voltage Reduction Mode when the calculated ambient air temperature is above 0°C (32°F); the calculated battery current is less than 2 amps and greater than -7 amps, and the generator field duty cycle is less than 99 percent. Its targeted generator output voltage is 12.9 volts. The BCM will exit this mode once the criteria are met for Charge Mode.

Start-up Mode

After the engine has started, the BCM sets a targeted generator output voltage of 14.5 volts for 20 seconds.

Windshield Deice Mode

After the engine has run for more than 10 seconds, the BCM sets a targeted generator output voltage of 13.8 volts if the calculated ambient air temperature is less that 0°C (32°F). The BCM will stay in this mode until the engine coolant temperature (ECT) reaches 75°C (167°F) for 10 minutes.

Battery Sulfation Mode

The BCM will enter this mode when the interpreted generator output voltage is less than 13.2 volts for 45 minutes. Once in this mode, the BCM will set a targeted output voltage of 13.8 volts for 5 minutes. The BCM will then determine which mode to enter depending on voltage requirements.

Charge Indicator Operation

The instrument panel cluster (IPC) illuminates the charge indicator in the message center when the one or more of the following occurs:

Charging System Failure

The BCM and the ECM will send a serial data message to the IPC for the CHARGING SYSTEM FAILURE message to be displayed. It is commanded ON when a charging system DTC is a current DTC. The message is turned OFF when the conditions for clearing the DTC have been met.

Battery Voltage

The IPC displays the system voltage as received from the BCM over the serial data circuit. If there is no communication with the BCM, then the display will read all dashes until communication is restored.

Battery Saver Active

The BATTERY SAVER ACTIVE message will display on the driver information center (DIC) when the vehicle enters a load shed 2 event. Refer to for load shed 2 setting criteria.

Charging System Description and Operation w/o RVC

The generator features the following major components:

The pulley and the fan cool the slip ring and the frame.

The generator features permanently lubricated bearings. Service should only include tightening of mount components. Otherwise, replace the generator as a complete unit.

The voltage regulator controls the rotor field current in order to limit the system voltage. When the field current is ON, the regulator switches the current ON and OFF at a rate of 400 cycles per second in order to perform the following functions:

At high speeds, the on-time may be 10 percent with the off-time at 90 percent. At low speeds, the on-time may be 90 percent and the off-time 10 percent.

The generator provides voltage to operate the vehicle's electrical system and to charge its battery. A magnetic field is created when current flows through the rotor. This field rotates as the rotor is driven by the engine, creating an AC voltage in the stator windings. The AC voltage is converted to DC by the rectifier bridge and is supplied to the electrical system at the battery terminal.

When the engine is running, the generator turn-on signal is sent to the generator from the powertrain control module (PCM), turning ON the regulator. The generator's voltage regulator controls current to the rotor, thereby controlling the output voltage. The rotor current is proportional to the electrical pulse width supplied by the regulator. When the engine is started, the regulator senses generator rotation by detecting AC voltage at the stator through an internal wire. Once the engine is running, the regulator varies the field current by controlling the pulse width. This regulates the generator output voltage for proper battery charging and electrical system operation. The generator F-terminal is connected internally to the voltage regulator and externally to the PCM. When the voltage regulator detects a charging system problem, it grounds this circuit to signal the PCM that a problem exists. The PCM monitors the generator field duty cycle signal circuit.

The instrument panel cluster (IPC) illuminates the charge indicator in the message center when the following occurs: