Principles of Operation

PRINCIPLES OF OPERATION

The powertrain control module (PCM) controlled charging system determines the optimal voltage setpoint for the charging system and communicates this information to the voltage regulator. This system is unique in that it has 2 unidirectional communication lines between the PCM and the generator/regulator. Both of these communication lines are pulse-width modulated (PWM). The generator communication (GEN COM) line communicates the desired setpoint from the PCM to the voltage regulator. The generator monitor (GEN MON) line communicates the generator load and error conditions to the PCM. The third pin on the voltage regulator, the A circuit pin, is a dedicated battery voltage sense line.

The charging system voltage is controlled by the PCM. The generator charges the battery, and at the same time supplies power for all of the electrical loads that are required. The battery is more effectively charged with a higher voltage when the battery is cold and a lower voltage when the battery is warm. The PCM is able to adjust the charging voltage according to the battery temperature by using a signal from the intake air temperature (IAT) sensor. This means the voltage setpoint is calculated by the PCM and communicated to the regulator by a communication link.

The PCM simultaneously controls and monitors the output of the generator. When the current consumption is high or the battery is discharged, the system is able to increase the idle speed.

To minimize the engine drag when starting the engine, the PCM controls the generator. The generator does not produce any output until the engine has started.

The PCM then progressively increases the output of the generator. The PCM controls the operation of the charging system warning indicator in the instrument cluster. The PCM is responsible for turning the charging system warning indicator off after the engine is started and illuminating it under fault conditions (when the generator is not generating the correct amount of current with the engine running). The charging system warning indicator is also illuminated by the PCM at key ON engine OFF, and stall condition.

This is a System 4 charging system, which uses the GEN MON and GEN COM lines to control and monitor the charging system through the PCM. System 4 charging systems are virtually identical in design and therefore, share the same diagnostics. The circuit numbers and colors may be different, but the functions are the same. System 4 charging systems may use any type of generator, as the generator type usually depends on the engine packaging and/or output requirements versus cost.

Circuit Description

Battery Positive Output (B+) Terminal Circuit 38 (BK/OG)
The generator output voltage is supplied through the battery positive output (B+) terminal circuit 38 (BK/OG) on the rear of the generator to the battery and electrical system.

A Circuit 35 (OG/LB)
The A circuit or battery sense circuit is used to sense battery voltage. This voltage is used by the regulator to determine generator output. This circuit is also used to supply current to the generator field (rotor). The amount of current supplied to the rotor determines generator output.

Circuit 3204 (LG/OG)
The GEN MON circuit communicates the generator load and error conditions to the PCM.

Circuit 904 (LG/RD)
This is the GEN COM circuit. The PCM determines the optimal voltage setpoint for the charging system and communicates this information to the voltage regulator on the GEN COM circuit.