HV Battery Charge Failure

Fig 1: Charge Indicator Lamp

Courtesy of CHRYSLER GROUP, LLC

The Dash Charge Indicator Lamp, mounted on the center of the instrument panel will have both outer LED segments (1 and 5) turn on and flash continuously in the event of a HV Battery charging failure. During this process the remaining segments (2, 3 and 4) will not be illuminated.

This condition has been referred to "goal post" illuminating on the Dash Charge Indicator Lamp. The "goal post" will flash with the vehicle off or in any ignition position (except for RUN). The "goal post" will NOT flash with the ignition turned to RUN.

REASONS FOR GOAL POST ILLUMINATION:

• If the contactors in the High Voltage Battery are not closed and the EVSE is plugged in. A DTC will set in the BPCM for contactor issues.
• If the manual service disconnect is out of the vehicle and the EVSE is then plugged into the vehicle.

  If the EVSE is unplugged at the wall socket before the EVSE is unplugged from the vehicle. DTC P0D27 will set in the OBCM.

• If any High Voltage component (BPCM, EAC, EVCU, OBCM, and PIM) sets an active DTC the "goal post" condition can exist during an active charging status. Verify if DTCs exist in these modules, and if any exist go diagnose those DTCs.
• If the ground at the wall receptacle is shorted or open.
• IF customer did not swipe their Charge Station card BEFORE plugging the EVSE in to the vehicle.
• If there is a fault within the EVSE (RED lamp on EVSE is illuminated) then charging will either stop or never start charging. Check the EVSE and see if the lights on the EVSE indicate a fault within.
• Extension cords could stop the high voltage battery charging process. Extension cords should not be used with EVSE's for high voltage battery charging.
• If the vehicle isn't charging at one EVSE Charging Station but will charge at another, then most likely this is not an issue with the vehicle. Do not replace components on the vehicle until the EVSE where the vehicle displayed "goal post" can be inspected.

GETTING THE VEHICLE TO CHARGE AFTER GOAL POST ILLUMINATION:

• ALWAYS disconnect the EVSE from the vehicle BEFORE disconnecting at the wall socket.
• Don't use an extension cord with EVSE's when charging the high voltage battery
• There have been EVSEs at Public Charging Stations that are inoperative. Do not replace components on the vehicle until you can verify there is nothing wrong with the EVSE where the vehicle displayed "goal post". Check the EVSE and see if the lights on the EVSE indicate a fault within (RED lamp illuminated on EVSE).

IF A GOAL POST EXISTS, NORMAL OPERATING PROCEDURE IS AS FOLLOWS:

• If the Ignition is in the RUN position the goal posts will NOT display/flash as the vehicle is designed to turn off the "goal post."
• If the ignition is in any other position, other than RUN, the "goal post" will flash continuously, if there is a charging issue present.
• The vehicle was designed to be driven if the "goal post" is on and the vehicle is in the RUN position. If "goal post" exists and there is an internal problem with the charging system the customer will be able to drive the vehicle. If the vehicle thinks the EVSE is still plugged in then this will prevent the customer from driving the vehicle when in the RUN position.

EDUCATE THE CUSTOMER ON HOW CHARGING WORKS:

1. Show the customer the indicators on the EVSE and how they should light when everything is working correctly and when there is a fault.
2. Show the customer how to plug the EVSE into the vehicle making sure you hear the click when correctly plugged into the vehicle.
3. Tell them how the LED segments on the Dash Charge Indicator Lamp work and what they mean
4. Teach them how long it can take to charge, etc.
5. Show the customer what "goal post" are. An easy way to show the customer "goal post" is to plug the EVSE into the vehicle inlet while holding down the button on the EVSE. When you let go of the button on the EVSE and plug into the vehicle inlet (you will hear a click if plugged into the vehicle correctly) the "goal post" will go away.

IF A GOAL POST EXISTS ON A VEHICLE, THE FOLLOWING MUST BE PERFORMED

1. If the customer brings a vehicle in and states their vehicle won't charge, confirm that at the dealership. Plug the customer's vehicle in to a good/known working charging station at the dealership. If the vehicle charges the problem most likely resides with the EVSE the customer tried charging at. If the vehicle will not charge at the dealership then there is a problem on the vehicle side. If the customer was using their Level 1 Charger ask them to see it, test it out, and verify if it is good or not.
2. Make sure the Manual Service Disconnect is properly seated in the High Voltage Battery Pack. If the Manual Service Disconnect was out of the vehicle and the ignition was turned ON or a vehicle door is opened then a DTC may have set in the BPCM. Clear that DTC from the BPCM and then try to charge the High Voltage Battery.
3. Diagnose ALL DTCs in High Voltage Components (OBCM, PIM, BPCM, EVCU, and EAC).
4. If the EVSE is plugged into the vehicle and "goal post" is displayed on the Dash Charge Indicator Lamp, unplug the EVSE from the vehicle. When you unplug the EVSE check again for "goal post" on the Dash Charge Indicator Lamp. If no "goal post" display then the issue is with the EVSE and NOT the OBCM or charging system.
5. Check the BPCM contactors. Try opening and closing the contactors using the procedure found in the WiTech tool under BPCM. The contactors need to be closed in order for the High Voltage Battery to charge
6. Perform a 12V Battery reset. Turn the Ignition OFF, and wait 10 minutes. Disconnect the 12V battery, wait another ten minutes, and then hook up the 12V battery again. This may cause the vehicle to reset itself and allow charging again.