Fusion FWD L4-2.5L Hybrid (2010)
High-Voltage Converter/Inverter
Principles of Operation - High-Voltage Cable Assembly
The high-voltage cable assembly contains 4 basic circuits:
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The high-voltage/high-amperage cables run between the HVTB and the eCVT.
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The high-voltage/low-amperage cables run from the HVTB to the DC/DC and the Air Conditioning Compressor Module (ACCM).
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The interlock circuit consists of small-gauge wiring wrapped around the high-voltage cables. It is a continuous, single circuit used to monitor the
integrity of the high-voltage connections. The interlock connectors are part of the high-voltage cable connectors and are either disconnected at the
same time as the high-voltage cable, or must be disconnected before the high-voltage cable depending upon the type of connection being serviced.
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The AC power point high-voltage wiring and LED indicator circuits between the DC/AC inverter and the AC power point.
All high-voltage wiring utilizes orange insulation as well as orange tape and/or harness tubing.
DC/AC Inverter and AC Power Point
High-Voltage Converter/Inverter
Principles of Operation - DC/AC Inverter and AC Power Point
The DC/AC inverter converts 12 volts DC to 110 volts AC to power a device that uses AC electricity with a rating of less than 150 watts. The 110 volts
AC created by the inverter will measure differently than a conventional AC outlet (utility-generated) with some multi-meters. The AC power point will
automatically shut off if the load exceeds 150 watts, to help prevent damage to the inverter or load. The inverter supplies 110 volts AC power only when
the ignition is in the ON/START position. This reduces the draw on the 12-volt system when the vehicle is not running. The AC power point is equipped
with a green LED that indicates the system integrity.
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Green LED illuminates continuously - ignition in ON/START and system is operating normally.
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Green LED flashes continuously - ignition in ON/START and a fault is detected.
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Green LED does not illuminate - ignition is not in ON/START, fault on the RUN/START circuit input to the DC/AC inverter or the DC/AC
inverter is not powered (fault with DC/AC inverter B+ or ground circuits).
Short circuits, overloads or overheating of the inverter will cause the green LED to flash and the power to be cut off to the outlet. If the LED is flashing,
the problem must be corrected (short circuit or excessive load). If the DC/AC inverter is overheated, it must be allowed time to cool off (without the load
connected). Refer to the Owner's Literature for a list of appropriate electrical loads/devices that can be used.
DC To DC Converter Control Module (DC/DC) System
High-Voltage Converter/Inverter
Inspection and Verification - DC to DC Converter Control Module (DC/DC) System
WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to
depower the system. The high-voltage hybrid system utilizes approximately 300 volts DC, provided through high-voltage cables to its
components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage
components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious
personal injury or death.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
