Escape PHEV TechInfo

Technical information on the Ford Escape useful when designing a Escape PHEV conversion.

Unless otherwise noted, everything refers to a 2007 year model, belonging to [| Hybrids Plus].

Traction battery

Removal

Battery pack lifted out of vehicle

Trunk after the battery was removed

From the hatch opening:

• Remove the carpet in the hatch compartment floor, to reveal the battery
• Turn the orange safety plug from LOCK to UNLOCK and pull it out
• Remove the black plastic air coupling on the rear-left
• Remove the bolts on either side of the battery (3 bolts on each side)
• Disconnect the battery:
  • Orange HV connector on the right (flip the lever)
  • Big black signal connector on the left (unscrews)
  • Small connector next to the signal connector (snaps)
• Hook an engine hoist to the two round holes in the black metal on either side of the battery
• Hoist the battery out of the car

To open the battery:

• You need a #35 security Torx driver, and a #35 Torx driver
• Remove all the screws in the 2 top covers
  • Cover over the fans
  • Cover over the batteries and electronics

Component locations

Battery pack opened, rear view

Battery pack opened, front view

The battery includes (as seen when in the vehicle):

• Air blowers in the rear compartment
• NiMH cells in the center
  • 2 layers of cells
  • each layer in a left and right group
  • each group has 13 columns of 5 cells in series
  • total: 2 * 2 * 13 * 5 = 260 cells
  • pack voltage: 1.3 V * 260 = 338 V
• controller on the right side
• contactors and HV connector on the right-front corner
• safety plug on the left-right corner
• the Converter on the left side

Block diagram

Block diagram of battery

This block diagram shows the main components of the battery pack, and how they interface to the vehicle

• The NiMH cells store energy
• The battery controller controls the battery pack
  • It communicates with the vehicle through the CAN bus
  • It monitors the air intake temperature, it controls the intake air flow and source, and it drives to DC blowers to blow air into the cells
  • It monitors the cells' voltage, including in intermediate points of the pack ("taps")
  • ...
• The DC-DC converter receives power from the 12 V battery and boosts it up to 300 V, to charge the traction battery when it's dead and the user presses the Jump Start button (by the driver's left foot)
• The Safety Disconnects opens the pack mid-voltage
• The HV Output section
  • It has a connector with 2 high-current contacts to connect the battery voltage to the vehicle
  • It has a pair of wires to determine if that connector is connected or not
  • It has contactors (high power relays) to connect or isolate the pack voltage
• The blower compartment has 2 DC blowers to blow air into the cells

Wiring diagram

Wiring diagram of battery.

This wiring diagram shows how the components of the battery pack are wired together.

• High voltage wires are red.
• Connectors are marked with their color and the number of positions
• Sets of wires are shown together. The slash at one end indicates the number of wires
• The function of sets of wires is shown above the wire
• The wire colors are shown below the set of wires
• Shaded squares indicate that wires are bundled together
• The orientation of the components is shown as seen when looking from the hatch

This reverse engineering drawing is not guaranteed to be accurate and is offered as-is. Please direct corrections to DavideAndrea.

Connectors

AC/DC connector (left) & Control connector (right)

The battery has 3 connectors, with a total of 34 wires:

• C4227A - 28 wires - control
• C4227B - 2 wires - low power HV to the AC/DC converter
• C4227C - 4 wires - traction HV, interlock signals

AC/DC converter connector: C4227B

The AC/DC converter connector has 2 circuits, with the following names and functions.

Group	Ckt	Pin(s)	Ext. color	Int. color	Name	Function	Notes
AC/DC converter in	3000	1	Vio	Red	AC/DC in+	???
	3001	1	VioOrg	Blk	AC/DC in-

Control connector: C4227A

The big control connector has 24 circuits, with the following names and functions.

Group	Ckt	Pin(s)	Ext. color	Int. color	Name	Function	Notes
12V pwr	57	35,36,37	LtgrnBlk	Blk	Ground	Power ground
	570	30,31	BlkWht	BlkWht	Ground	Signal ground
	3800	4,5,6	LtgrnBlk	Red	+12 V	Power +12V	Always on
	16	10,11	+12 V	RedLtgrn	RedBlu	Low power +12V	Always on
	3206	19	LtgrnYel	TanRed	Voltage supplied in Start and Run	Receives 12 V when the car is on	From the ignition switch. Overload protected
	3997	14	Dkgrn	Tan	Power sustain relay out	Receives 12 V when the Powertrain Control Module's Power Relay is on	The relay is located in the Battery Junction Box. The Powertrain Control Module is located under the hood, in the rear-center
Air intake	3703	21	BrnWht	BlkBrn	Battery compartment thermistor signal	Senses air intake temperature	All are located inside the column at the rear-left corner of car, inside air intake ducts
	3704	25	DkgrnWht	WhtBlk	Battery compartment thermistor return
	698	34	Red	RedBlu	Mode door actuator motor +	Moves a flap controlling air flow
	699	26	Org	BlkYel	Mode door actuator motor -
	1129	17	BrnWht	RedGRn	Mode door actuator potentiometer +	Senses position of flap
	1130	20	PnkLtgrn	BluBlk	Mode door actuator potentiometer wiper
	1128	24	GryLtBlu	BlkWht	Mode door actuator potentiometer -
	698	34	Red	RedBlu	Zone Valve	Solenoid selecting air source
CAN BUS	1908	29	Wht	YelRed	High speed CAN bus +	Communicates with vehicle	See CAN section below for messages
	1909	28	Blk	YelWht	High speed CAN bus -
Jump start switch	176	16	PnkLtgrn	BrnWht	Jump start switch feed	When grounded, lets 12 V battery jump charge-up the traction battery a bit, through DC-DC converter in battery pack, enough to start the car	The switch is located to the left of the driver's left ankle, behind a black plastic panel
	179	12	OrgRed	GrnBlk	Jump start switch illumination +	When at 12 V, it lights-up the switch
Emergency control	3003	8	VioWht	Tan	Battery power off signal	???	The Power Train Control Module is located under the hood, in the rear-center
	877	7,23	Wht	RedBlk	Fuel pump feed / Inertia Sw input	Normally at +12V; open in case a crash opens an inertia switch	The High Voltage Cutoff switch is located in the right-rear column of the car
	212	27	Dkblu	BlkBlu	Immediate shutdown 1	The Transaxle Control Module tells the battery to remove power to the vehicle?	The Transaxle Control Module is under the hood, in the center, to the left of the box labeled "HYBRID"
	213	13	DkbluYel	BlkRed	Immediate shutdown 2
Unused	n.a.	18	n.a.	TanRed	???	???	Connected to controller, not used in vehicle
		32		YelBlk

HV connector: C4227C

HV connector

The HV connector has 4 circuits, with the following names and functions.

Group	Ckt	Pin(s)	Ext. color	Int. color	Name	Function	Notes
HV	3180	+	Org	n.a.	HV+	Battery power	To Transaxle Control Module
	3181	-	Org		HV-
Interlock	3130	1	Gry	Wht or Blu	Traction Battery Control Module Interlock +	Detects if HV connector is mated	To Transaxle Control Module
	3181	2	Red	Blu or Wht	Traction Battery Control Module Interlock -

CAN bus messages

• Kvaser has a simple explanation of the CAN bus.
• wikipedia article on the CAN bus

General Disclaimer:   (HV) (DC) injury or death hazard,   use at your own risk,   may void warranty.

HV (High Voltage) DC (Direct Current) Warning: Traction Battery Packs, Motors, Chargers, and other HV sources could cause serious injury or death if proper precautions are not taken while working on or around such High Voltage Direct Current sources. Use this information at your own risk: There is no warranty expressed nor implied and we are not liable for any of your past, present, nor future actions. Even should you perform these modifications to the letter you could still damage any number of components in your vehicle causing it to no longer function. Even if it appears to function properly your actions may cause it to self destruct with collateral damage to surrounding properties other than your vehicle. By utilizing these ideas and instructions in an attempting to enhance national security, reduce gas consumption, vehicle "emissions", your carbon footprint, or smog, you do so at your own risk & peril. Warranty: In performing some of these modifications you may void your warranty with the vehicles manufacturer. See also our My wiki:General disclaimer talk:Disclaimer