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• Remote HV Front End

Remote HV Front End

Introduction

This fixture tests HVFEs rev D (the Unit Under Test - UUT).

Schematic

Hardware description

The fixture is powered by a wall mount power supply. When connected to the UUT, the fixture does the following:

• It powers the UUT
• It routes the K1 output to the Precharge- input, and the supply to the Precharge+ input
  • When K1 is active (on) this applies the supply across the precharge inputs
• It uses the K2 output to drive a DPDT relay (also named K2)
  • When K2 is active (on) this applies the supply voltage between the B+ and Chassis inputs
• It uses the K3 output to drive a DPDT relay (also named K3)
  • When K3 is active (on) this applies the supply voltage between the Chassis and B- inputs
  • R1 discharges the voltage across the B+ and B- inputs, so that there is no voltage when K3 is not energized

Software description

• Test no contactors - Fail if the Voltage Absent line is active
• Test Prechg Off - Fail if the Voltage Absent line is active
• Test B+ Off - Fail if the Voltage Absent line is active
• Test B- Off - Fail if the Voltage Absent line is active

• Test K1 -> Prechg - Fail if the Voltage Absent line is inactive

• Test K2 -> B+ - Fail if the Voltage Absent line is inactive

• Test K3 -> B- - Fail if the Voltage Absent line is inactive

• Test CAN - Fail if the CAN machine does not see the termination resistor
• Test low current sensor - Fail if there should be a low current sensor, yet its reading is outside the 2.25 to 2.75 V range
• Test high current sensor - Fail if there should be a high current sensor, yet its reading is outside the 2.25 to 2.75 V range
• Test pack voltage off - Fail if the pack voltage reading is not 2 A/D counts or below
• Test pack voltage on- Fail if the pack voltage reading is outside the range of 49 mV +/- 10 % (10 counts +/- 1 count)
• Passed

Set up

• Program the UUT with the test program
• Plug the UUT into the test fixture
• Plug in the test fixture to the AC

Procedures

• Connect the 7-pin white connector to the UUT, BATT connector
• Insert the terminal at the end of the white wire connector to the UUT, CHASSIS hole
• Connect the 7-pin black connector to the UUT, CTRL connector
• Listen for the rapid clicking of the relays in the test fixture, and look flashing of LEDs on the UUT
• Afterward, note that LED H9 is on (not blinking), that LEDs H4, and H9 are on, and no other LED is on
  • If H9 is blinking, note which LEDs are on (H1, 2, 3, 6, 7 and 8), and look for the result in the table below
• Disconnect the UUT

Results