ALL FORD KUGA 2011 1.G Workshop Manual

SECTION 414-05 Voltage Converter/Inverter
VEHICLE APPLICATION:
2008.50 Kuga
PAGE
CONTENTS
DESCRIPTION AND OPERATION
414-05-2
Direct Current/Alternating Current (DC/AC) Inverter (Component Location)......................
414-05-3
Direct Current/Alternating Current (DC/AC) Inverter (Overview)........................................
414-05-3
Function indicator...............................................................................................................
414-05-4
Direct Current/Alternating Current (DC/AC) Inverter (System Operation and Component
Description) .......................................................................................................................
414-05-4
System Diagram.................................................................................................................
414-05-4
System Operation...............................................................................................................
414-05-4
DC/AC converter.............................................................................................................
414-05-5
Component Description......................................................................................................
414-05-5
DC/AC converter.............................................................................................................
414-05-5
AC mains outlet...............................................................................................................
REMOVAL AND INSTALLATION 414-05-7
Direct Current/Alternating Current (DC/AC) Inverter.......................................................... 414-05-1
Voltage Converter/Inverter
414-05-1
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Direct Current/Alternating Current (DC/AC) Inverter – Overview
Function indicator
WARNING: For workshop repairs, it is only
permissible to replace the converter as a
complete unit together with the wiring
harness and the socket. The component
must not be opened, as charged capacitors
inside can still carry dangerously high
residual voltages.
The LED in the socket lights up orange when the
converter is supplying a voltage.
In the event of a fault the system switches off and
indicates the cause of the fault by flashing a trouble
code via the LED in the socket:
• 1x flash – High temperature
• 2x flashes – Overload
• 3x flashes – Internal overvoltage
• 4x flashes – Internal undervoltage
• Continuous flashing – Short circuit to power
If the converter switches off due to high
temperature then it switches back on again
automatically once the temperature has cooled
down sufficiently.
With all of the other faults which are displayed, the
converter can be reset by switching the ignition off
and back on again or by unplugging and reinserting
the consumer in the socket.
If these measures are unsuccessful then there are
no further options for directly influencing the
function yourself. G1055637en
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Voltage Converter/Inverter
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Component Description
DC/AC converter
The converter operates with a series connection
of two power converter circuits. The primary power
converter here is a push-pull converter. It converts
the 12 V supply from the electrical system of the
vehicle to an intermediate direct current link of
approx. 320 V.
From this intermediate direct current link, the
downstream full H-bridge circuit generates a
pulse-width modulated output voltage with 230
V/50 Hz.
A controller modulates the pulse width of the
square-wave output voltage and maintains an
effective output voltage of 230 V under varying
load conditions and under different input voltages.
Here, the rising and falling edge of the positive and
negative square wave pulse are controlled
symmetrically to the ideal shape of a sine wave,
which - among other things - also makes a positive
contribution to electromagnetic compatibility.
DC/AC converters which supply a modified square
wave output voltage are referred to as 'Modified
Sine Wave Inverters".
With this type of system there is no need for a
residual current operated device for protection in
the event of accidental contact, as all of the 230 V
lines are double-insulated. Potential-free separation
of the entire 230 V voltage part from the vehicle is
provided (electrical isolation).
The output voltage of 230 V/50 Hz is not generated
until the switching voltage is present at terminal 1
of the converter via the AC mains outlet switch.
The converter operates with the ignition switched
on and a vehicle electrical supply of between 11
V and 16 V. Internal voltage monitoring in the converter deactivates the system if the input
voltage is outside this range.
AC mains outlet
Description
Item
230 V/50 Hz outlet
1
LED (light emitting diode)
2
Cover3 Description
Item
230 V/50 Hz outlet (for UK vehicles)
1
LED2
Cover3
In order to prevent accidents and the risk of
electrical shock, the outlet is protected with a child
safety device and the AC outlet switch.
In order to make the system safer for children, the
safety catches for the 230 V contacts can only be
pushed to one side by pressing a Euro plug evenly
into both of the connector openings.
The AC mains outlet switch only activates the
system when a consumer is connected to the
outlet. G1055639en
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Direct Current/Alternating Current (DC/AC) Inverter
Removal
1.
Refer to: Floor Console (501-12 Instrument
Panel and Console, Removal and Installation).
2. 3.
G1065580en
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5.
G1065580en
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6.
Installation
1.
To install, reverse the removal procedure. G1065580en
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Audio System
Refer to Wiring Diagrams Section 415-01, for
schematic and connector information.
Refer to Wiring Diagrams Section 415-03, for
schematic and connector information.
General Equipment
The Ford approved diagnostic tool
Inspection and Verification
NOTE: If the keycode is entered incorrectly 3 times,
the system will allow the next keycode in 30
minutes. After entering the keycode the 10th time
incorrectly the system will lock out. The component
can only be unlocked by the manufacturer.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual Inspection Chart Electrical
Mechanical
– Fuse(s)
– Wiring harness
– Electricalconnector(s)
– Audio unit
– Audio control switch (if equipped)
– CD changer
– Central junction box (CJB)
– Audio unit
– Antenna
– Foreign objects
contacting speaker
– Trim poorly fitted/resonance
– Audio control switch (if equipped)
– Compact disc (CD) changer
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the Self-Diagnostic Mode.
Self-Diagnostic Mode - Low Series
Audio Unit
NOTE: The audio unit must be in radio mode
before entering the Self-Diagnostic Mode.
1. To enter the audio unit Self-Diagnostic Mode, switch the audio unit ON. Within four seconds
depress the preset buttons 3 and 6 together.
2. Release the preset buttons 3 and 6 and the audio unit will enter the Self-Diagnostic Mode. 3.
The Self-Diagnostic Mode will automatically stop
after one iterration or to interrupt it , switch the
audio unit OFF.
Self-Diagnostic Mode Circuit Tested
Message Displayed
Right hand front woofercircuit
1. 4CH RF low
Right hand fronttweeter circuit.
2. 4CH RF high
Left hand front woofercircuit.
3. 4CH LF low
Left hand front tweetercircuit.
3. 4CH LF High
Right hand rear woofercircuit
1. 4CH RR low
Right hand rear tweetercircuit
2. 4CH RR high
Left hand rear woofercircuit
3. 4CH LR low
Left hand rear tweetercircuit.
3. 4CH LR High
Antenna connection
Seek 87.5 - 108.0
4. If the cause is not evident after the Self-Diagnostic Mode, connect the Ford
approved diagnostic tool to the data link
connector (DLC).
Self-Diagnostic Mode - High Series
Audio Unit GEN 2
NOTE: The audio unit must be in radio mode
before entering the Self-Diagnostic Mode.
1. To enter the audio unit Self-Diagnostic Mode, switch the audio unit ON. Within four seconds
depress the preset button 3 and 6 together.
2. Release the preset button 3 and 6 and the audio
unit will enter the Self-Diagnostic Mode.
3. The Self-Diagnostic Mode will automatically stop
after one iterration or to interrupt it , switch the
audio unit OFF.
Self-Diagnostic Mode Circuit Tested
Message Displayed
Right hand front woofercircuit
RF speaker 600Hz G1055068en
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Circuit Tested
Message Displayed
Right hand fronttweeter circuit.
RF speaker 8kHz
Left hand front woofercircuit.
LF speaker 600Hz
Left hand front tweetercircuit.
LF speaker 8kHz
Right hand rear woofercircuit
RR speaker 600Hz
Right hand rear tweetercircuit
RR speaker 8kHz
Left hand rear woofercircuit
LR speaker 600Hz
Left hand rear tweetercircuit.
LR speaker 8kHz
Antenna connection
Seek 87.5 - 108.0
4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
5. If the cause is not visually evident, verify the symptom and refer to the diagnostic tab within
the Ford approved diagnostic tool. G1055068en
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Information and Entertainment System -
General Information
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Cellular Phone
Refer to
Wiring Diagrams Section 415-00, for
schematic and connector information. General Equipment
Ford diagnostic equipment
Principles of Operation
NOTE: Voice control will only operate with the
audio unit and components required switched ON.
Voice Control
The portable support electronics (PSE) module
has a voice control system. The customer will be
able to push the VOICE button on the audio control
switch located on the steering column lower
shroud, this will activate the PSE module and allow
voice control. An audible tone will be heard through
the audio unit speakers after which, a voice
command can then be spoken into the microphone
located in the overhead console.
The incoming calls and voice confirmation can be
heard through the audio system speakers.
When a voice command is spoken into the
microphone it will be sent as a signal to the PSE
module. The signal is then sent from the PSE
module to the relevant components on the
medium-speed controller area network (CAN) bus
network. The component will then convert the
signal back into the original voice command.
The components that the PSE module interacts
with are as follows:
• audio unit
• navigation system display module
• cellular phone
For additional information on the cellular phone
system, REFER to the cellular phone Owner's
Guide.
Bluetooth
An input can be given through the cellular phone
with or without the cellular phone connected to the
handset holder. Providing that the cellular phone
is one of the recommended cellular phones for the
system, is supplied with the Bluetooth technology
and the cellular phone is programmed to the PSE
module.
When selected as active the Bluetooth technology
is a wireless system that interacts with the relevant component modules through the PSE module. The
general operation of the Bluetooth is similar to the
voice control.
Bluetooth technology cannot transfer the cellular
phone's PHONEBOOK or recent outgoing and
incoming call details to the audio unit or navigation
system display module. If the cellular phone is
placed into the handset holder the PHONEBOOK
data and recent outgoing and incoming call
information will be transferred to the audio unit or
navigation system display module.
For additional information, REFER to the cellular
phone Owner's Guide.
Inspection and Verification
NOTE: Make sure that the cellular phone is
featured on the list of recommended cellular
phones for the system.
Make sure that the PSE module and cellular
phone are configured to each other before
starting a system diagnosis. ENTER the
following PIN number on the cellular phone to
configure the cellular phone to the PSE module:
0000.
Make sure that the MUTE symbol is not
displayed on the audio unit when trying to
operate the cellular phone system. If the MUTE
symbol is displayed, this indicates that the PSE
module requires configuring to the vehicle and
the cellular phone requires programming to the
PSE module. GO to
Pinpoint Test C.
1. Verify the customer concern by operating the system using the customers cellular phone.
2. Visually inspect for obvious signs of electrical damage.
Visual Inspection Chart Electrical
• Fuse(s)
• Wiring harness
• Electrical connector(s)
• Cellular phone
• Microphone
• PSE module
• Audio unit
• Instrument cluster
• Navigation system display module G1189085en
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3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, connect the Ford diagnostic equipment to the data link
connector (DLC).
5. SELECT the TOOLBOXmenu.
6. SELECT the ENTERTAINMENT/COMMUNICATION menu.7. SELECT the
SPEECH RECOGNITION
MODULE option and follow the instructions on
the display.
8. Retrieve the diagnostic trouble codes (DTC)s and refer to the Diagnostic Trouble Code (DTC)
Index Chart.
9. If no DTCs are retrieved or there is no communication with the module, proceed to the
Symptom Chart to continue diagnostics.
Diagnostic Trouble Code (DTC) Index Chart Action
Possible Source
Description/Condition
DTC
GO toPinpoint Test B.
Microphone defect or
short to ground
Microphone input circuit
failure
B1038
REFER to:Charging
System (414-00 Char-
ging System - General
Information, Diagnosis and Testing).
Battery voltage above
16 volts
Battery voltage high
B1317
REFER to:Charging
System (414-00 Char-
ging System - General
Information, Diagnosis and Testing).
Battery voltage below 9
volts
Battery voltage low
B1318
INSTALL a new PSEmodule. TEST the
system for normal oper- ation.
PSE module
PSE module failure
B1342
GO toPinpoint Test B.
Microphone defect or
not connected
Microphone input signal
circuit open
B1899
GO toPinpoint Test B.
No supply to micro-
phone
Microphone bias circuit
failure
B2272
REFER to the Ford
diagnostic equipment.
PSE module
Faulty module configura-
tion
B2477 G1189085en
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