Circuit/System Description
The radiator coolant temperature (RCT) sensor is a variable resistor that measures the temperature of the engine coolant in the radiator. The engine control module (ECM) supplies 5 volts to the RCT signal circuit and supplies a ground to the low reference circuit.
The following table illustrates the difference between temperature, resistance, and voltage
| RCT | RCT Resistance | RCT Signal Voltage |
|---|---|---|
| Cold | High | High |
| Warm | Low | Low |
The engine control module (ECM) controls the pulse width modulated (PWM) thermostat. The thermostat controls coolant flow and regulates the engine operating temperature. Ignition voltage is supplied directly to the thermostat. The ECM controls the thermostat by grounding the control circuit with a solid state device called a driver. The driver is equipped with a feedback circuit that is pulled-up to a voltage. The ECM can determine if the control circuit is open, shorted to ground, or shorted to a voltage by monitoring the feedback voltage.
The hybrid powertrain control module 2 (HPCM 2) controls the radiator cooling fans with a pulse width modulated (PWM) signal to the cooling fan control modules. The HPCM 2 supplies a regulated 12 volts to the engine control module (ECM) via the cooling fan output circuit. The ECM modulates the output circuit to ground to request operation of the engine radiator cooling fans in response to predetermined internal combustion engine (ICE) coolant temperatures. The ECM also uses requests from the HPCM 2, along with any other inputs, such as the need for power electronics, high voltage battery, or HVAC cooling to determine the total percentage of cooling fan operation in a range of 0-100 percent. The ECM cooling fan output circuit is controlled with a solid state device called a driver. The driver is equipped with a feedback circuit which is pulled up to a voltage within the controller. The ECM can determine if the output circuit is open, shorted to ground, or shorted to a voltage by monitoring the feedback voltage.
The engine control module (ECM) monitors temperature difference between the engine coolant temperature (ECT) sensor and the radiator coolant temperature (RCT) sensor during a cold start-up. The purpose of this diagnostic is to analyze the engine coolant thermostat for being stuck open.
Cooling System Description and Operation
This vehicle is equipped with three fully independent cooling systems. The power electronics cooling system is dedicated to cooling the battery charger and the power inverter module. The battery cooling system is dedicated to cooling and heating the high voltage battery. The engine cooling system is dedicated to cooling the engine and providing heat to the passenger compartment.
The engine cooling system consists of a radiator, two 12 volt pulse width modulated (PWM) radiator fans, a 12 volt coolant pump, a coolant flow control valve, a high voltage heater and a heater core.
Scheme 1
The hybrid/EV powertrain control module 2 controls the radiator cooling fans. The cooling fans are controlled with a Pulse Width Modulated (PWM) signal. The hybrid/EV powertrain control module 2 diagnoses any faults with the hardwire circuit to the engine control module. The engine control module sends a fan request PWM signal to the hybrid/EV powertrain control module 2 through a hardwire circuit. The hybrid/EV powertrain control module 2 operates in a pass-through mode for the engine control module fan request. The higher the duty cycle the higher the cooling fan speed.
The hybrid/EV powertrain control module 2 sends a request to the engine control module for the cooling fans to be turned on. The engine control module uses this request and other vehicle inputs to decide if and what speed the cooling fans should operate. The engine control module sends the cooling fan command to the hybrid/EV powertrain control module 2. The hybrid/EV powertrain control module 2 sends the signal to the cooling fans to operate and at what speed.
If the vehicle is in Charge Mode and the hybrid/EV powertrain control module 2 requests the cooling fans to operate, if the engine control module is not awake, the hybrid/EV powertrain control module 2 will control the cooling fans. If active cooling is needed, the engine control module wakes up to operate the air conditioning control module and then the engine control module is the master controller for the fans.
Scheme 2
The HVAC Control Module turns on the coolant pump and monitors the temperature sensors in the passenger compartment, engine radiator, high voltage heater and the engine to determine the position of the coolant flow control valve and if the high voltage heater is needed. Passenger compartment heat is provided by air flowing through the heater core. The heater core is heated by coolant from either the engine or the high voltage heater.
The engine cooling system circulates a 50/50 mixture of DEX-COOL and distilled water.