Hybrid & EV / OBC

ONBOARD CHARGER

Converts external AC power into controlled high-voltage battery charging current.

OUTPUT GUIDE103/111
CONTROL STRATEGYHigh-voltage power electronics: evaluate approved service data and only use properly rated isolated equipment.

Correct theory and operation

HOW IT
WORKS.

Separate controller command, loaded circuit behavior and useful mechanical or thermal output.

01

Controlled output

Converts external AC power into controlled high-voltage battery charging current.

02

Driver strategy

Identify the installed actuator and driver from vehicle-specific service information. Test only the applicable circuit; different constructions require different connections and equipment.

03

Current reveals load

Current rise, running level, commutation and turn-off behavior expose winding condition, resistance and mechanical loading.

04

Feedback closes the loop

Position, pressure, speed, temperature or current feedback may be separate from the actuator circuit and must agree with command.

Common mistakes

AVOID THE
FALSE CLUE.

Interpreting the recorded data

Normal data pattern

Use approved low-voltage signals or scan data to compare requested operation, input conditions, output and feedback. A converter, inverter or high-voltage load has no universal safe test point or known-good waveform.

Fault indications

Requested operation with missing or unstable output, protection events or feedback disagreement warrants system-specific checks. Verify prerequisites and low-voltage supplies first. Only appropriately trained personnel should make high-voltage measurements with the prescribed equipment and isolation procedure.

COMPLETE TEST SEQUENCE

  1. Capture DTCs, commands and operating conditions before disconnecting anything.
  2. Verify power and ground under load with the actuator commanded.
  3. Measure command voltage and current together using approved connections.
  4. Compare electrical behavior with physical, hydraulic or thermal output.
  5. Check feedback, learned limits and required calibration.
  6. Repeat the original condition and confirm the repair.
DO NOT JUMPER IT BLINDLY

Know the driver design, current limit, feedback circuit and safety consequences before applying external power.

ACTUATOR LIBRARYReturn to all actuators→

Diagnostic details

Construction & type-specific testing

Identify the installed design before testing. Construction, signal format and redundant channels are separate attributes; use only the procedure for the actual component.

Onboard Charger

COMPLETE TEST SEQUENCE

  • 1. Capture DTCs, commands and operating conditions before disconnecting anything.
  • 2. Verify power and ground under load with the actuator commanded.
  • 3. Measure command voltage and current together using approved connections.
  • 4. Compare electrical behavior with physical, hydraulic or thermal output.
  • 5. Check feedback, learned limits and required calibration.
  • 6. Repeat the original condition and confirm the repair.