2014 Flex Workshop Manual

SECTION 414-05: High Voltage Converter/Power Point Inverter	2014 Flex Workshop Manual
DIAGNOSIS AND TESTING	Procedure revision date: 05/02/2013

High-Voltage Converter/Power Point Inverter

Special Tool(s)
	Flex Probe Kit 105-R025D or equivalent

Symptom Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. REFER to Diagnostic Methods in Section 100-00 for more information.

Symptom Chart
Condition	Possible Sources	Action
No power at the AC power point or the AC power point LED indicator flashes with the key in the ON position	Overloaded DC/AC inverter Inverter timed-out with engine not running Overheated DC/AC inverter Fuse(s) Wiring, terminals or connectors DC/AC inverter AC power point	DISCONNECT all electrical accessories from the AC outlet and VERIFY that cabin temperature is below 75 C (166.9 F). CYCLE the ignition. TEST the system for normal operation. If the system is operating normally, RETURN the vehicle to the customer. If the AC outlet LED indicator is still flashing, GO to Pinpoint Test A .
The DC/AC inverter does not operate correctly — the AC power point LED indicator is never on	Fuse Wiring, terminals or connectors DC/AC inverter AC power point	GO to Pinpoint Test B .
The AC power point turns off after 13 minutes	BCM DC/AC inverter Wiring, terminals or connectors	GO to Pinpoint Test C .

Pinpoint Tests

Pinpoint Test A: No Power at the AC Power Point or the AC Power Point LED Indicator Flashes with the Key in the ON Position

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for more information.

Refer to Wiring Diagrams Cell 44 , Power Distribution/SJB for schematic and connector information.

Normal Operation

NOTE: The electrical device that is powered by the AC power point must not exceed 150 watts.

NOTE: If the green LED is flashing, the AC power point may be overloaded, overheated or shorted. Unplug the electrical device from the AC power point and cycle the key. Refer to the Owner's Literature to determine if the electrical device is appropriate for the AC power point.

This pinpoint test is intended to diagnose the following:

Fuse(s)
Wiring, terminals or connectors
DC/AC inverter
AC power point

Visual Inspection and Diagnostic Pre-checks

Verify that any device being used in the AC outlet is rated at less than 150 watts
Verify the AC outlet is not being used with the engine off for a period longer than 13 minutes without starting the engine or cycling the ignition
Verify the cabin temperature is less than 75 C (166.9 F)
Inspect BJB fuse 17 (30A)
Inspect BCM fuse 32 (15A)
Inspect for a damaged AC outlet

PINPOINT TEST A: NO POWER AT THE A/C POWER POINT OR THE AC POWER POINT LED INDICATOR FLASHES WITH THE KEY IN THE ON POSITION

Test Step

Result / Action to Take

A1 CHECK THE POWER OUTLET LED STATUS

Ignition OFF.
Start the engine.
Check the green LED on the AC outlet.
Is the green LED flashing?

Yes
GO to A2 .

No
If the green LED is NOT illuminated, CHECK fuse 17 (30A) and fuse 32 (15A). If OK, GO to Pinpoint Test B . If not OK, identify the possible cause of the circuit short.

Refer to Wiring Diagrams Cell 44 , Power Distribution/SJB for schematic and connector information.

If the green LED is illuminated continuously, the DC/AC inverter may have timed-out after 13 minutes of operation without the engine running. VERIFY correct system operation with a device rated at less than 150 watts. If there is still no power at the AC outlet, GO to A2 .

A2 CHECK THE POWER SUPPLY CIRCUITS FOR VOLTAGE

Ignition OFF.
Disconnect: DC/AC Inverter C4210.
Ignition ON.
Measure the voltage between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C4210-5	CBP32 (GN/VT)	—	Ground
C4210-6	SBB17 (RD)	—	Ground

Are the voltages greater than 10 volts?

Yes
GO to A3 .

No
CHECK fuse 17 (30A) and fuse 32 (15A). If OK, REPAIR the open circuit on the affected circuit(s). If not OK, identify the possible cause of the circuit short.

Refer to Wiring Diagrams Cell 44 , Power Distribution/SJB for schematic and connector information.

A3 CHECK THE GROUND CIRCUIT FOR AN OPEN

Ignition OFF.
Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C4210-12	GD349 (BK/GY)	—	Ground

Is the resistance less than 5 ohms?

Yes
GO to A4 .

No
REPAIR the circuit.

A4 CHECK THE AC OUTLET CIRCUITS FOR AN OPEN

Disconnect: AC Outlet C301.
Disconnect: DC/AC Inverter C4210.
Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C4210-1	HYA01 (OG/GN)	C301-1	HYA01 (OG/GN)
C4210-7	HYA02 (OG/WH)	C301-3	HYA02 (OG/WH)

Are the resistances less than 5 ohms?

Yes
GO to A5 .

No
REPAIR the circuit(s).

A5 CHECK THE AC OUTLET CIRCUITS FOR A SHORT TOGETHER

Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C4210-1	HYA01 (OG/GN)	C4210-7	HYA02 (OG/WH)

Is the resistance greater than 10,000 ohms?

Yes
GO to A6 .

No
REPAIR the circuits.

A6 CHECK THE AC OUTLET CIRCUITS FOR A SHORT TO GROUND

Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C4210-7	HYA02 (OG/WH)	—	Ground
C4210-1	HYA01 (OG/GN)	—	Ground

Are the resistances greater than 10,000 ohms?

Yes
GO to A7 .

No
REPAIR the affected circuit(s).

A7 CHECK THE AC OUTLET FOR AN OPEN

Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C301-3 (component side)	HYA02 (OG/WH)	Outlet Face-1	HYA02 (OG/WH)
C301-1 (component side)	HYA01 (OG/GN)	Outlet Face-2	HYA01 (OG/GN)

Are the resistances less than 5 ohms?

Yes
INSTALL a new DC/AC inverter. REFER to Direct Current/Alternating Current (DC/AC) Inverter .

No
INSTALL a new AC outlet. REFER to Alternating Current (AC) Power Point .

Pinpoint Test B: The DC/AC Inverter Does Not Operate Correctly — The AC Power Point LED Indicator is Never On

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for more information.

Refer to Wiring Diagrams Cell 44 , Power Distribution/SJB for schematic and connector information.

Normal Operation

The DC/AC inverter receives 12 volts DC on circuits SBB17 (RD) and CBP32 (GN/VT) and is grounded on circuit GD349 (BK/GY). The incoming DC power is internally converted to 60 Hz 110 volts AC power that is output to the AC power point on circuits HYA01 (OG/GN) (power) and HYA02 (OG/WH) (neutral). If a fault in the system is detected, the LED flashes when the key is in the ON position. The LED continuously illuminates if the system is operating correctly when the key is in the ON position. The DC/AC inverter supplies 12V DC to the LED along circuit LYA03 (YE/VT). The LED is grounded through the DC/AC inverter on circuit RYA03 (BU/BN).

This pinpoint test is intended to diagnose the following:

Fuse(s)
Wiring, terminals or connectors
DC/AC inverter
AC power point

Visual Inspection and Diagnostic Pre-checks

Inspect BJB fuse 17 (30A)
Inspect BCM fuse 32 (15A)
Inspect for a damaged AC outlet

PINPOINT TEST B: THE DC/AC INVERTER DOES NOT OPERATE CORRECTLY — THE AC POWER POINT LED INDICATOR IS NEVER ON

Test Step

Result / Action to Take

B1 CHECK THE SYSTEM OPERATION

Start the engine.
Connect a device with a rating of less than 150 watts to the AC outlet and verify power supply at the AC outlet.
Is power available at the AC outlet to operate the device?

Yes
GO to B2 .

No
GO to Pinpoint Test A .

B2 CHECK THE LED CONTROL CIRCUITS FOR AN OPEN

Disconnect: DC/AC Inverter C4210.
Disconnect: AC Outlet C301.
Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C4210-10	LYA03 (YE/VT)	C301-6	LYA03 (YE/VT)
C4210-11	RYA03 (BU/BN)	C301-5	RYA03 (BU/BN)

Are the resistances less than 5 ohms?

Yes
GO to B3 .

No
REPAIR the affected circuit(s).

B3 CHECK THE AC OUTLET LED

Test the diode in both directions:
Is the resistance greater than 10,000 ohms in one direction and between 10-20 ohms in the opposite direction?

Yes
INSTALL a new DC/AC inverter. REFER to Direct Current/Alternating Current (DC/AC) Inverter .

No
INSTALL a new AC outlet. REFER to Alternating Current (AC) Power Point .

Pinpoint Test C: The AC Power Point Turns Off After 13 Minutes

Diagnostic Overview

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for more information.

Refer to Wiring Diagrams Cell 13 , Power Distribution/SJB for schematic and connector information.

Normal Operation

The DC/AC inverter receives a signal from the BCM over the LIN whenever the engine is running. If the DC/AC inverter does not receive this message for 13 minutes, the inverter stops supplying 110 volts to the power outlet and the green LED indicator flashes. The system can be reset by cycling the ignition from ON to OFF and back to ON, however the system only operates for another 13 minutes unless the signal is received from the BCM that the engine is running.

This pinpoint test is intended to diagnose the following:

BCM
DC/AC inverter
Wiring, terminals or connectors

Visual Inspection and Diagnostic Pre-checks

Verify the concern by monitoring the AC outlet LED indicator for 13 minutes with the engine running. If the LED indicator starts to flash after 13 minutes, continue to the pinpoint test. If the system continues to operate normally after 13 minutes, make sure the customer is aware of the DC/AC inverter time-out function.

PINPOINT TEST C: THE AC POWER POINT TURNS OFF AFTER 13 MINUTES

Test Step

Result / Action to Take

C1 RETRIEVE BCM DTCS

Enter the following diagnostic mode on the scan tool: Self Test — BCM .
Record any BCM DTCs retrieved.
Is U0100:00 present in the BCM ?

Yes
REFER to Section 419-10 to diagnose the DTC.

No
GO to C2 .

C2 CHECK THE LIN COMMUNICATION CIRCUIT FOR A SHORT TO GROUND

Ignition OFF.
Disconnect: BCM C2280B.
Disconnect: DC/AC Inverter C4210.
Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C4210-9	VDN01 (BU/WH)	—	Ground

Is the resistance greater than 10,000 ohms?

Yes
GO to C3 .

No
REPAIR the circuit.

C3 CHECK THE LIN COMMUNICATION CIRCUIT FOR AN OPEN

Measure the resistance between:

Positive	Lead	Negative	Lead
Pin	Circuit	Pin	Circuit
C4210-9	VDN01 (BU/WH)	C2280B-52	VDN01 (BU/WH)

Is the resistance less than 5 ohms?

Yes
INSTALL a new DC/AC inverter. REFER to Direct Current/Alternating Current (DC/AC) Inverter . TEST the system for normal operation. If the AC outlet still turns off after 13 minutes when the engine is running, INSTALL a new . REFER to Section 419-10 .

No
REPAIR the circuit.