ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

414-05 Voltage Converter-Inverter|Removal and Installation > < Generator - 1.8L Duratorq-TDCi (Lynx) Diesel, Vehicles Without: Air Conditioning
Voltage Converter/Inverter - Direct Current/Alternating Current (DC/AC) Inverter C-MAX 2003.75 (06/2003-)
Description and Operation

WARNING:
WARNING:For workshop repairs, it is only permissible to replace the converter as a complete unit together with the wiring harness and the socket. The component must not be opened, as charged capacitors inside can still carry dangerously high residual voltages.

In the rear part of the center console there is an optional 230 V socket instead of the outlet of the standard 12 V electrical system.

In this case a DC/AC converter supplies a continuous power of 150 W at 230 V/50 Hz. It can also absorb temporary power peaks of up to 300 W when consumers are switched on.

For example, an output of 150 W is sufficient to run laptops, games consoles and mobile phone chargers.

  • DC/AC converter
  • AC mains outlet wiring harness
  • AC mains outlet

Function indicator

WARNING:
WARNING:For workshop repairs, it is only permissible to replace the converter as a complete unit together with the wiring harness and the socket. The component must not be opened, as charged capacitors inside can still carry dangerously high residual voltages.

The LED in the socket lights up orange when the converter is supplying a voltage.

    In the event of a fault the system switches off and indicates the cause of the fault by flashing a trouble code via the LED in the socket:

  • 1x flash
    -
    High temperature
  • 2x flashes
    -
    Overload
  • 3x flashes
    -
    Internal overvoltage
  • 4x flashes
    -
    Internal undervoltage
  • Continuous flashing
    -
    Short circuit to power

If the converter switches off due to high temperature then it switches back on again automatically once the temperature has cooled down sufficiently.

With all of the other faults which are displayed, the converter can be reset by switching the ignition off and back on again or by unplugging and reinserting the plug in the socket.

If these measures are unsuccessful then there are no further options for directly influencing the function yourself.

DC/AC converter

The converter operates with a series connection of two power converter circuits. The primary power converter here is a push-pull converter. It converts the 12 V supply from the electrical system of the vehicle to an intermediate direct current link of approx. 320 V.

From this intermediate direct current link, the downstream full H-bridge circuit generates a pulse-width modulated output voltage with 230 V/50 Hz.

A controller modulates the pulse width of the square-wave output voltage and maintains an effective output voltage of 230 V under varying load conditions and under different input voltages. Here, the rising and falling edge of the positive and negative square wave pulse are controlled symmetrically to the ideal shape of a sine wave, which - among other things - also makes a positive contribution to electromagnetic compatibility.

DC/AC converters which supply a modified square wave output voltage are referred to as 'Modified Sine Wave Inverters".

With this type of system there is no need for a residual current operated device for protection in the event of accidental contact, as all of the 230 V lines are double-insulated. Potential-free separation of the entire 230 V voltage part from the vehicle is provided (electrical isolation).

The output voltage of 230 V/50 Hz is not generated until the switching voltage is present at terminal 1 of the converter via the AC mains outlet switch.

The converter operates with the ignition switched on and a vehicle electrical supply of between 11 V and 16 V. Internal voltage monitoring in the converter deactivates the system if the input voltage is outside this range.

AC mains outlet

The AC mains outlet switch only activates the system when a consumer is connected to the outlet.

The contacts of the outlet exert a more powerful grip on the plug so that it does not shake loose on poor road surfaces. An orange LED lights up to show that the unit has been activated.

  • 230 V/50 Hz outlet
  • LED (light emitting diode)
    -
    230 V/50 Hz outlet

AC mains outlet

In order to prevent accidents and the risk of electrical shock, the outlet is protected with a child safety device. Here, a safety catch is released by the long center contact of the plug when the plug is inserted.

  • 230 V/50 Hz outlet (for UK vehicles)
  • LED
    -
    230 V/50 Hz outlet

414-05 Voltage Converter-Inverter|Removal and Installation > < Generator - 1.8L Duratorq-TDCi (Lynx) Diesel, Vehicles Without: Air Conditioning