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In this article, we will have a close look at the electrical charging systems in VE/WM model vehicles.
EPM/RVC Overview
Complete control of the charging system gives improved fuel economy, reliable engine idle and improved battery life.
The EPM system also signals the driver if problems exist in the charging system. The Instrument Panel Cluster (IPC)
alerts the driver to these system problems.
Monitoring of more variables affecting vehicle charge, compared to conventional voltage sensing at the alternator
gives greater control over charging conditions.
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EPM Communication Methods:
GMLAN Definitions:
Periodic: Transmission of Data occurs at fixed intervals. An active network means continual data transmission.
For example, The EBCM transmits wheel speed information to the ECM every 10ms. The BCM transmits the VIN
number on the LS GMLAN every 5 seconds.
Event: Transmission of data occurs in response to events. For example, the “hazards on” message transmits when
you switch on the hazard lights. Turning the hazard lights off fires a “hazards off” message.
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The EPM system performs three functions:
2. It takes corrective actions by boosting idle speeds and adjusting the regulated voltage.
When the ignition is on, using the calculated SOC as a starting point, estimating the “live” SOC depends on the
following parameters:
Current into versus current out of the battery
Battery capacity
When the battery is disconnected, the BCM will calculate that the battery is only 20% charged when reconnected,
regardless of the actual state of charge of the battery. The BCM does not rely on voltage readings over a short time
to evaluate battery charge. The BCM takes 8 hours of ignition connection to relearn the actual battery state of charge.
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Charging System Operation Modes
There are four main EPM charging modes that are available.
Idle Boost Mode Regulated Voltage Control (RVC) Mode
Load Shed Mode Fuel Economy Mode
The estimated battery temperature is between 0°C (32°F) and 70°C (158°F)
The calculated battery current is less than +15 amps and greater than −8 amps
Its targeted alternator output voltage is the open circuit voltage of the battery and can be between 12.5–13.1 volts.
The BCM will exit this mode and enter normal RVC Mode when any of the conditions described above are present.
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The alternator in the EPM system uses the L terminal, (was used for the charging light) and the F terminal, (a long
time ago this was used for external regulator connection) for quite different functions, which will be discussed fully
in the Engine Control Module section.
Conventional alternators work as constant voltage generators, the current output is continually changing. Calcium
batteries used in VE/WM have different charge requirements to traditional lead acid batteries. Calcium (Ca) batteries
require “4 stage charging”; due to their chemical properties, they prefer higher voltages than lead acid units do.
Calcium batteries also prefer different current limiting and different charging voltages depending on their state of
charge.
The conventional alternator does not have current limiting control; it controls charging by generating a constant
voltage, which is always slightly higher than fully charged battery voltage requirements, approximately 14.2 volts.
Under heavy electrical load, the conventional alternator supplies a lot of current, up to its maximum rated capacity
to retain the preset output voltage. Under light electrical load, the conventional alternator supplies current until it
reaches the preset output voltage. When the voltage exceeds the set point, the alternators‟ voltage regulator reduces
the field winding current, so reducing the alternator current output.
Fixed output voltage is a compromise between adequately charging the battery under heavy electrical load and not
overcharging the battery under light loads.
Battery voltage does not change quickly enough to reflect rapid changes in engine load conditions, caused by
increases in electrical load or AC turning on, so the conventional alternator does not limit its output quickly enough
to unload the engine. The EPM system reads these changes directly through the associated sensors connected to the
BCM and the ECM. The EPM system, on finding a sudden increase in engine load, commands the alternator to stop
charging. Rapidly unloading the engine in this way prevents stalling.
The BCM tells the ECM it needs a certain output voltage. The ECM, in turn, directs the alternator to supply this output
voltage. The alternator then tells the ECM how hard it is working. This signal from the alternator indicates how much
current it is producing to achieve the specified output voltage. Alternator communication signals are Pulse Width
Modulated (PWM).
The BCM receives net charge information from the Battery Current Sensor and monitors the battery Voltage through
the Battery Sense Voltage Line. The BCM determines the desired output of the alternator and sends the information
to the ECM. The ECM controls the alternator through the PWM signal it sends to the L terminal, connected to the
alternator field circuit. The ECM monitors the duty cycle of the alternator field. The ECM reads the duty cycle, via the F
terminal, and sends this information to the BCM via the GMLAN bus.
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The BCM also estimates battery temperature based on ambient temperature and net charge to refine its view of the
battery‟s state of charge (SOC).
This 3 wire Hall Effect device generates a pulse width modulated signal,
the duty cycle is proportional to ground current through the earth strap.
The BCM reads the signal.
The L Terminal is the command signal from the ECM to the alternator.
Normal duty cycle is between 10–90 %. Signals between 0–10 % and 90–100 %
are for diagnostic purposes.
The table to the right maps the commanded duty cycle presented to the L terminal
against the output voltage of the alternator:
The alternator feeds back information via the F terminal. This information informs the ECM how hard it is working.
The ECM in turn relays this information to the BCM. The BCM may make a decision to turn off unnecessary electrical
loads if the alternator is not coping. As an example if the headlamps, window wipers, heated rear window and
entertainment system are on the BCM orders 70% output to the ECM. The ECM will then send a 70% duty cycle signal
to the alternator. The extreme load on the alternator would cause a 95% PWM signal back to the ECM. The BCM on
receiving this information from the ECM may switch off the heated rear window. Under lighter current load a 70%,
command to the alternator may produce a 30% response. This means the alternator is able to maintain the required
voltage while working at one third of its total capacity. Similar to the L Terminal signal, the Normal duty cycle of the
F terminal is between 5–95%. Duty cycle outside this range is for diagnostic purposes.
This allows the ECM to adjust the idle speed to compensate for high electrical loads. The ECM monitors the status of
the alternator load. When the key is in the RUN position and the engine is OFF, the ECM should detect a duty cycle
near 0 percent. When the engine is running, the duty cycle should be between 5–95 percent. Typical values seen in
Scan Tool Data for Engine ⇒ Electrical, for L and F signals would be 70-75% for L, commanding about 14.4 volts from
the alternator and anywhere between 30-95% signal on the F terminal. The high value (99%) is full electrical load at
idle with a battery not fully charged, the low value is low electrical load. Remember if you see 100% duty cycle
reported on F terminal the alternator could be faulty. We will cover system diagnosis towards the end of this paper.
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Instrument Panel Cluster (IPC):
The IPC provides a means of customer notification in case of EPM failure. This BCM provides EPM information to the
IPC via the GMLAN Low speed bus.
There are two fault indicators displayed by the IPC:
Charge indicator
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Charging System Diagnostics
The first step to accurate charging diagnosis is the use of the
correct testing equipment.
The reading should be a minimum of 12.4 volts for the VE/WM Calcium battery.
If the battery requires charging, connect the charger leads to the jump-start posts, not the battery terminals.
The charge current then flows through the sensing ground lead and the BCM will have a clearer idea of the state of
charge (SOC) of the battery.
We will now look at how Tech 2 can help in diagnosing charging faults.
Many modules in the vehicle detect low/high voltage problems and set a DTC. We will concentrate on DTC‟s directly
related to the charging system only.
Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
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Conditions for Setting the DTC:
With the engine running, the ECM detects a PWM signal less than 5 percent for at least 15 seconds (DTC P0625:
Generator F Terminal Low Voltage).
With the engine running, the ECM detects a PWM signal of 100 percent for at least 15 seconds (DTC P0626: Generator
F Terminal High Voltage).
Circuit/System Verification:
With the scan tool installed, ignition ON and the engine running, observe the alternator-F Terminal Signal parameter
in the ECM data list. The alternator-F Terminal Signal parameter should read between 5 and 95 percent.
Circuit/System Testing:
1. Verify that a test lamp illuminates between the generator B+ circuit terminal 1 X2 and ground.
⇒ If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high
resistance.
3. Ignition ON, verify the scan tool ECM GEN-F Terminal Signal parameter displays less than 5 percent.
⇒ If greater than the specified range, test the signal circuit terminal 2 for a short to voltage. If the circuit
tests normal, replace the ECM.
4. Install a 3 A fused jumper wire between B+ and the signal circuit terminal 2.
5. Verify the scan tool ECM GEN-F Terminal Signal parameter displays greater than 95 percent.
⇒ If less than the specified range, test the signal circuit terminal 2 for a short to ground or an open/high
resistance. If the circuit tests normal, replace the ECM.
6. If the circuit tests normal replace the Alternator with the correct Holden Genuine replacement Part.
We are producing a crude signal equivalent to 0% with the test light not contacting, to 100% with the test
light contacting the F terminal harness side. The Tech 2 should show these two inputs in the data list display,
unless there is a problem in the harness to ECM.
⇒ If the test lamp did not affect the alternator-F Terminal Signal parameter, test the alternator-F
Terminal Signal circuit for a short to ground or an open/high resistance. If circuit tests normal, replace the
ECM.
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Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, prior to using this diagnostic test.
Circuit/System Description:
The engine control module (ECM) uses the alternator turn ON signal circuit to control the load of the alternator on
the engine. A high side driver in the ECM applies a PWM signal to the voltage regulator. This signals the output
voltage, which the alternator produces. The ECM monitors the state of the alternator F terminal. The ECM should
detect low voltage on the alternator turn on signal circuit when the ignition is ON and the engine is OFF or when the
charging system malfunctions. With the engine running, the ECM should detect high voltage on the alternator turn
on signal circuit. The ECM performs key ON and RUN tests to determine the status of the alternator turn on signal
circuit.
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Scan Tool Reference:
Engine Control Module Scan Tool Data List
Circuit/System Testing:
1. With ignition ON and the engine OFF disconnect the alternator harness at the alternator and measure
the voltage of the alternator turn on signal circuit should read near 0 volts.
⇒ If greater than, 0 volts test the alternator turn on signal circuit for a short to voltage. If circuit test
is normal, replace the ECM.
2. With ignition ON and the engine running, the voltage of the alternator turn on signal circuit should read over
3.5 volts.
⇒ If no voltage is measured, test the alternator turn on signal circuit for a short to ground or an open/high
resistance. If circuit tests normal replace the ECM.
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Current Sensor DTC
DTCB1516 08: Battery Current Sensor Performance Signal Invalid
Diagnostic Fault Information:
Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, prior to using this diagnostic procedure.
Circuit/System Description:
The battery current sensor supplies a PWM input signal to the body control module (BCM).
Circuit/System Testing:
1. Ignition OFF, disconnect the harness connector at the battery current sensor.
2. Ignition OFF for 90 seconds, test for less than 5 ohms between the low reference circuit terminal B and
ground.
⇒ If greater than the specified range, test the low reference circuit for an open/high resistance.
3. Ignition ON, test for 4.8–5.2 volts between the 5-volt reference circuit terminal A and ground.
⇒ If less than the specified range , test the 5-volt reference circuit for a short to ground or an open/high
resistance. If the circuit tests normal, then replace the BCM.
⇒ If greater than the specified range, test the 5-volt reference circuit for a short to voltage. If the circuit tests
normal, then replace the BCM.
4. Ignition ON, test for 4.8–5.2 volts between the signal circuit terminal C and ground.
⇒ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the
circuit tests normal, replace the BCM.
⇒ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal,
replace the BCM.
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BCM Voltage DTC
DTCB1517 00: Battery Voltage Below/Above Threshold
Circuit/System Description:
The body control module (BCM) has designated circuits for monitoring vehicle system voltage. The BCM monitors the
system voltage to keep the voltage within the correct range. Damage to components and incorrect data may occur
when the voltage is out of range. The BCM monitors the system voltage over an extended length of time. If the BCM
detects the system voltage is outside an expected range for the calibrated length of time or the BCM battery sense
circuits differ by 3 volts, DTC B1517 will set. Other modules also monitor system voltage. The system voltage message
is sent to the other modules and will default to 12.9 volts.
Circuit/System Testing
1. Measure and record the battery voltage.
⇒ If more than 1 volt difference between battery voltage and the power circuit then test the applicable circuit
for a short to ground or an open/high resistance. If the circuits/connections test normal, replace the
telematics module.
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Circuit/System Description:
The body control module (BCM) monitors the state of charge (SOC) of the electrical system. If the BCM senses that the
SOC at key-on is 30 percent lower than what it was when the engine was running, DTC B1527 will set.
Circuit/System Testing
1. Ignition ON, with the scan tool compare the Previous State of Charge and Start Up State of Charge
parameters. The readings should not differ by more than 30 percent.
- If the readings differ by more than 30 percent, refer to Battery Electrical Drain/Parasitic Load Test.
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Charging System Check
If these tests check out OK then we need to carry out a charging system
check.
Note: Remember to wear Safety Glasses when working with batteries.
Connect a DMM set on volts (20 volts range) to the alternator positive
terminal and a known good ground.
Record the voltage reading on the DMM. Connect a suitable loading device to the battery positive and negative posts.
While observing the scan tool, increase the engine speed to 1300 RPM.
Observing the Current Clamp reading, the amperage should be 5.0–10 amps and the DMM voltage should read
between 13.8–15.4 volts.
1. While observing the scan tool, increase the engine speed to 1900 RPM.
2. Observe the DMM adjust the loading device to 90 percent of the alternators maximum output.
3. Observe the DMM voltage should read between 13.8–15.4 volts.
4. Adjust the loading device until the DMM reads 13.5 volts.
5. Observe the DMM the amperage should read maximum output of alternator (100 amps or more).
6. Stop the engine.
7. Remove test equipment.
If the alternator voltage readings are outside the limits above or the current is below 100 amps
then replace the alternator.
Reproduction in whole or in part prohibited without written approval to Editor – Go Torque, Holden Aftersales
Department, 191 Salmon Street Port Melbourne
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