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The Chevrolet Volt high-voltage battery charging system consists of four main components: The drive motor battery charger cable, the vehicle charge port (including receptacle), the battery charger and the hybrid/EV battery pack. A variety of mechanical, visual and audio indicators/devices are used to communicate/interface with the customer or other user of the charging equipment.
The drive motor battery charger cable provided with the vehicle features a standard household electrical plug on one end and a plug designed to interface with the vehicle charge port receptacle on the other end. The drive motor battery charger cable features a charge current interrupt device with AC power, fault and missing earth indicators and it is stored beneath the vehicle's load floor. An optional 230/240 V charge station is also available to some customers who want to reduce the amount of time needed to recharge the high-voltage battery. The 230/240 V charge station is hard-wired to a 230/240 V power supply and mounted to the wall in the customer's garage. The 230/240 V charge station features the same plug on the vehicle end as the drive motor battery charger cable.
The drive motor battery charger cable has three indicators on it. The AC present indicator becomes permanently green when AC voltage is present at the wall plug. The Fault Indicator becomes permanently red for a current trip or failed self check. The Missing Earth Indicator becomes permanent red when no earth is detected at the wall outlet.
The battery charger is supervised and controlled by the hybrid/EV powertrain control module 2. The hybrid/EV powertrain control module 2 is the primary controller, and all diagnostic trouble codes will set in that module even though some of the diagnostics are actually run within the battery charger. Charging events can be delayed at customer request to take advantage of lower rates during non-peak hours. The status of charging events, including delays, is communicated to the user through visual indications (instrument panel mounted charge status indicator) and audio tones (charge status enunciator). The vehicle charge status indicator, located at the top middle of the instrument panel, will be permanently green when the vehicle is charging under automatic control. It will have a fast flash green if the charging is delayed and will begin later. It will have a slow flash green when charging is complete. A permanent yellow indicator means the vehicle is not able to accept a charge. If there is no indicator, the drive motor battery charger cable is not working properly or not connected.
The vehicle receptacle is located behind the charging port door on the driver's side front wing. The receptacle is accessed by pressing a switch located on the inside of the driver's door.
The hybrid/EV battery charger is a serviceable assembly containing several micro-processors, two separate high-voltage chargers and a single low-voltage charger. It is mounted behind the passenger side headlamp assembly, is programmable and communicates via serial data. Engine coolant is used to ensure that the charger does not exceed its maximum designed operating temperature. The low-voltage charger is used to ensure that the 12 V battery does not become depleted during a charge event, while one of the high-voltage chargers is used with a 120 V charge source and both are used with a 240 V charge source.
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