Theory Of Operation

The Integrated Dual Charge Module (IDCM) is a 7.2 kW Power Inverter and is comprised of the following two integral modules:

• On Board Charging Module (OCBM):  Converts the AC voltage from the Electric Vehicle Supply Equipment (EVSE) Charging Port to a Direct Current (DC) voltage for the High Voltage Battery.
• Auxiliary Power Module (APM):  Converts the high voltage DC power from the High Voltage Battery to a low voltage DC power for charging the Low Voltage Battery.

The IDCM is used to charge the Low Voltage and High Voltage Batteries. The IDCM is a stand alone module that does not contain any serviceable parts inside, but does have full diagnostic and programming capabilities through the vehicle Controller Area Network (CAN) C-EPT Bus.

The IDCM uses 2 Wake-up circuits, which notifies and allows the High Voltage Modules to operate. The Hybrid Control Processor (HCP) Module, also known as the Power Inverter Module (PIM), sends a wake-up signal to all high voltage modules through the Master Wake-Up circuit. The Battery Pack Control Module (BPCM) also sends a wake-up signal to IDCM through the PIM Wake-Up circuit, which the IDCM sends to the HCP Module.

The IDCM uses the Power Electronics Cooling Loop to remove the heat it generates. The IDCM monitors its internal temperature, voltage and current flow, and if any of these items are out of range, the IDCM will not operate.

Vehicle Charging Port:  The vehicle is equipped with plug-in charging capabilities. This allows the high voltage Battery to charge when the Electric Vehicle Supply Equipment (EVSE) Charging Cable is plugged into the vehicle's Society of Automotive Engineers (SAE) J1772 Charge Port.

The SAE J1772 Charge Port is connected to the IDCM through a dedicated 5 circuit wire harness. The SAE J1772 Charge Port supplies AC voltage to the IDCM, which converts the AC voltage to DC voltage. The IDCM supplies the DC voltage to the High Voltage Battery Pack to maintain a proper State Of Charge (SOC) for the high voltage Battery.

Low Voltage Charging:  The APM part of the IDCM converts energy to the 12.0 volt system, because a Generator is not used on this vehicle. The IDCM is also used as a DC to DC convertor (300.0 volts to 12.0 volts and 12.0 volts to 300.0 volts).

For the IDCM to operate, the IDCM must detect a minimum of 10.0 volts from the 12.0 volt Battery, along with a wake up signal from the HCP Module through the EPT ECU Wake-Up Signal circuit.

High Voltage Charging:  The OBCM part of the IDCM is responsible for monitoring and controlling the plug-in power supply to charge the high voltage battery. The OBCM also sends the high voltage to the Accessory Power Module (APM), which then converts the high voltage to low voltage for proper SOC of the 12 volt low voltage system.

When the EVSE Charging Cable is connected to the vehicle, the IDCM converts the incoming AC voltage to suitable DC battery voltage, then steps up the voltage level for proper charging. The IDCM regulates voltage and current flow to maintain proper State Of Charge (SOC) and State Of Health (SOH) of the high voltage Battery system.