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I01�High-voltage�Components

9.�Range�Extender�Electrical�Machine

143

Size

Value

Nominal�voltage

250 V

Continuous�power,�electrical

about�23.3 kW�electrical�DC�power�at�4300 rpm

and�330 V�DC

Efficiency

about�94%

Outer�diameter

about�300 mm

Length

about�115 mm

Weight

about�26 kg

The�range�extender�electrical�machine�is�supplied�by�Valeo.

Installation�location�of�the�range�extender�electrical�machine

Index

Explanation

Rear�axle�module

Range�extender�electrical�machine

Range�extender�(W20�engine)

Summary of Contents for I01

Page 1: ...Technical training Product information BMW Service I01 High voltage Components...

Page 2: ...elates to the European version of left hand drive vehicles Some operating elements or components are arranged differently in right hand drive vehicles than shown in the graphics in this document Furth...

Page 3: ...ector 10 2 4 Connections for potential compensation lines 12 3 Electric Motor 14 3 1 Electrical machine 14 3 1 1 Designation and identification of electrical machines 14 3 1 2 Technical data 16 3 1 3...

Page 4: ...rging plug 92 6 1 5 Electric Vehicle Supply Equipment 93 6 2 AC charging with 3 7 kW Occasional Use Cable 97 6 2 1 Wiring diagram 99 6 2 2 Charging cable 100 6 2 3 What must be observed when charging...

Page 5: ...es 147 9 4 2 Electrical interfaces 149 9 4 3 Coolant connections 149 10 REME 150 10 1 Introduction 150 10 2 Installation location and mounting 150 10 3 Connections at REME 152 10 3 1 Low voltage conne...

Page 6: ...the high voltage battery 176 12 3 Pinpointing isolation faults 176 12 4 Start up of the high voltage system 176 13 Operating Strategy 178 13 1 Operating strategy with pure electric drive 178 13 2 Ope...

Page 7: ...voltage components in the I01 Index Explanation 1 Electric heating 2 High voltage battery 3 Range extender electrical machine 4 Range Extender Electrical Machine Electronics 5 Electrical machine elec...

Page 8: ...afety rules proceed exactly as per repair instructions see also chapter Prerequisites The diagnosis and repair of the high voltage components is only allowed in a retail service center that has qualif...

Page 9: ...the possible hazards that can result from the high electric voltages used High voltage component warning sticker The high voltage cables are a special case for identification As they may be a few met...

Page 10: ...ing any work the vehicle must be secured against rolling away engage the parking lock of the transmission and activate the parking brake Terminal 15 and terminal R must be switched off Disconnect any...

Page 11: ...an be felt The high voltage safety connector cannot be disconnected from each other completely When the high voltage safety connector is pulled out far enough the message OFF is visible The high volta...

Page 12: ...e system is not switched on again without the knowledge and consent of the Service employee 2 2 4 Verifying safe isolation from the supply In BMW Service the de energized state is not verified using a...

Page 13: ...he Check Control message is not displayed you must not carry out any work on high voltage components Refueling the vehicle while the high voltage battery is charging is not permitted When the charging...

Page 14: ...igh voltage interlock loop is interrupted by removing the bridge the high voltage system shuts down automatically This is an additional safety precaution as the Service employee has already switched o...

Page 15: ...the high voltage component after reaching position A This may damage the connector on the high voltage components The high voltage connector of the high voltage cables must be pulled out at a right an...

Page 16: ...5 High voltage interlock loop connector bridge 2 3 2 Removing the round high voltage connector The procedure described here applies for removing the round high voltage connector in the I01 The followi...

Page 17: ...h voltage component is thus removed While the locking elements are further pushed together the connector must be removed lengthways in the direction of arrow 1 When reconnecting the high voltage cable...

Page 18: ...gh voltage cable to the EKK and to the electric heating the voltage supply of the EKK or transmission control unit runs via the bridge If one of the circuits is interrupted this also results in an aut...

Page 19: ...ents If in the event of a repair the high voltage components or the potential compensation lines are replaced the following must be observed during assembly The galvanic connection between the housing...

Page 20: ...esignation is used This short designation is used to assign an electrical machine to an electrical machine family For instance the short designation EMP242 is also used Position Meaning Index Explanat...

Page 21: ...er 2 Designation i a w GS 90023 3 Country of manufacture 4 Revision index 5 Part number 6 Adjustment value angle for rotor position sensor 7 Production date 8 Unified Parts Group The electrical machin...

Page 22: ...xcited synchronous machine Transverse flow machine 5 6 Torque 0 to e g 25 250 Nm 7 Type test concerns changes that require a new type test A B to Z Standard Acc to requirements e g adaptations to leng...

Page 23: ...s whereby the efficiency is increased in comparison to a conventional synchronous machine The impressive performance data are summarized in the following table Nominal voltage 360 V Nominal current 40...

Page 24: ...nergy regeneration Power and torque diagram for IB1P25B machine compared to the N52B30U1 engine The power and torque diagram shown here is not the full load diagram Instead the data was recorded at a...

Page 25: ...engine speeds However it is sufficient to be able to dynamically overtake in the speed range on national roads The characteristic of the maximum power can be deduced from the characteristic of the max...

Page 26: ...otor 20 3 1 3 Design Electrical machine Design of electric motor Index Explanation 1 Coolant ducts 2 Grooved ball bearing 3 Drive shaft 4 Inner housing 5 Stack of sheets in the rotor 6 Permanent magne...

Page 27: ...es not have an oil filling Only the two grooved ball bearings which include a grease filling are lubricated The cooling of the electrical machine is effected using coolant which is conveyed from the o...

Page 28: ...temperature there are two temperature sensors in the electrical machine of the I01 Both temperature sensors are located in the coils of the stator The temperature of the rotor is not measured directl...

Page 29: ...ngle setting of the rotor The rotor position sensor is mounted by the manufacturer of the electrical machine at the corresponding alignment so that it is already correctly adjusted A precise adjustmen...

Page 30: ...of electrical machine coming from the electrical machine electronics 6 Bore holes thread for the mechanical connection with the transmission 7 Drive shaft 8 Anti roll bar link connection The electric...

Page 31: ...ut shaft right 3 Transmission housing 4 X sealing ring 5 Output shaft left 6 Transmission input shaft with gearing 7 O sealing ring 8 Bore holes for the mechanical connection with the electrical machi...

Page 32: ...nds this and to avoid damage by water passing through However due to the big temperature differences which may occur during operation there is a need for pressure compensation This is effected via the...

Page 33: ...o transmitted to the rear axle module and ultimately supported at the body The entire drive unit electrical machine electrical machine electronics and transmission is also connected to the rear axle m...

Page 34: ...responding points on the housing of the electrical machine The threaded inserts for mounting the EKK cannot be replaced 3 1 5 Electrical interfaces The electrical machine has electrical interfaces for...

Page 35: ...ly of the signal lines of the following sensors Temperature sensors of stator coil 2x Temperature sensor of rotor at a bearing Rotor position sensor The electrical machine electronics measures the ele...

Page 36: ...r driving off or for shifting gears Gear selector switch I01 The transmission in the I01 is operated using a mono stable rotary gear selector switch The gear selector switch offers the option of selec...

Page 37: ...E The EME control unit activates the parking lock actuator directly It behaves similarly with the function of the other drive positions R and D Also here the EDME control unit calculates the logic par...

Page 38: ...al cage and drives the differential The differential distributes the torque to two outputs and enables the engine speed adjustment between the two outputs The differential has an almost identical desi...

Page 39: ...n the transmission Skeletal graphic for transmission Index Explanation M1 Torque of the electrical machine Transmission input torque M2 Transmission output torque M2 2 Drive torque at an output shaft...

Page 40: ...a the air flowing by at the transmission housing and the connection for the electrical machine The temperature in the transmission remains in a range up to a maximum 120 C for which the components and...

Page 41: ...h shafts have gearing However there is no intended centring for the two shafts When joining the transmission and the electrical machine the procedure described in the repair instructions must be follo...

Page 42: ...holes arranged on the transmission housing hold the aluminium screws for connecting the housing of the transmission and the electrical machine The aluminium screws must be replaced after disassembly I...

Page 43: ...taking off unintentionally as long as a charging cable is connected The parking lock of the I01 cannot be disengaged if a connected charging cable is identified Structure and operating principle The p...

Page 44: ...tput shaft left 11 Intermediate shaft Structure of the mechanical part of the parking lock Index Explanation 1 Bar 2 Return spring 3 Fixing element 4 Cam disc with two locking positions 5 Relay shaft...

Page 45: ...connected to the parking lock via a multi tooth connection of the actuator driving shaft at the transmission interface Attention The vehicle must be secured against rolling away by other measures e g...

Page 46: ...ctronics EME entirety 2 PT CAN connection 3 Voltage supply 4 EME control unit 5 Output stage for parking lock module 6 Electric motor 7 Transmission of the parking lock actuator 8 First position senso...

Page 47: ...the electrical machine electronics with a measurement Check the wiring harness section for open circuit short circuit The diagnosis system not only supports the Service employee during troubleshootin...

Page 48: ...veral components control units are also involved here The master role for the control of the electric motor in the I01 is assumed by the engine control It is modelled after vehicles with a gasoline en...

Page 49: ...I01 High voltage Components 3 Electric Motor 43 System wiring diagram for the drive control...

Page 50: ...Charging interface module LIM 16 Range Extender Digital Engine Electronics RDME 17 Range Extender Electrical Machine Electronics REME 18 EKK 19 Electrical machine electronics EME 20 Secondary air pum...

Page 51: ...omponents 3 Electric Motor 45 Activation of the electrical machine Heat management Evaluation of the electronic gear selector switch Shift by Wire function Power management for the low voltage vehicle...

Page 52: ...I01 High voltage Components 3 Electric Motor 46 Activation of the electrical machine Input Output for the drive control...

Page 53: ...driving readiness is established The EDME also queries whether all subsystems of the electrical drive train are functioning trouble free which is also a prerequisite for the provision of a drive torqu...

Page 54: ...at the same time Change from P or R to N or D only when selector lever is operated at the same time Automatic engaging of P P is automatically engaged from the other drive positions at vehicle stands...

Page 55: ...n for the low voltage vehicle electrical system The power management in the low voltage vehicle electrical system includes the following subfunctions Determination of the current energy requirement of...

Page 56: ...light switch and brake light test switch inverse redundant signals actuated not actuated supply via terminal R Local interconnect network bus Reading of the signals from the IBS and control of the el...

Page 57: ...3 Electric Motor 51 Torque coordination driver s choice assist systems Operating strategy Shift by Wire Low voltage power management Heat management Activating the electrical vacuum pump Fault managem...

Page 58: ...located in an aluminium housing The control unit of the bidirectional AC DC converter for the conversion of the AC voltage to direct current voltage for charging the high voltage battery as well as c...

Page 59: ...ical machine electronics the part of the luggage compartment panel shown in the graphic must first be removed A then visible lid must also be removed thereby creating an opening for Service The lid is...

Page 60: ...our categories Low voltage connections High voltage connections Connections for potential compensation lines Connections for coolant lines The following graphic shows all connections of the electrical...

Page 61: ...EKK 15 High voltage cable for the EKK 16 High voltage cable for electric heating 17 High voltage cable for AC charging 18 Ground connection Low voltage connections In the multipolar low voltage connec...

Page 62: ...vehicle electrical system with energy These two lines are not connected to the electrical machine electronics via a plug connection but a screw connection The connections of the electrical machine el...

Page 63: ...chine supply and sensor signals Signals of the two temperature sensors in the electrical machine The following graphic summarizes again the low voltage connections of the electrical machine electronic...

Page 64: ...ler 14 Output stage for the activation of the parking lock module 15 Output stage for the activation of the electrical vacuum pump 16 Terminating resistor for PT CAN 17 Terminating resistor for PT CAN...

Page 65: ...t blades High voltage interlock loop Convenience charging electronics Two pin Direct current voltage 1 shielding per line Flat high voltage connector with mechanical lock Cover over the contact blades...

Page 66: ...lectrical machine electronics Index Explanation 1 Convenience charging electronics 2 Electrical machine 3 High voltage battery 4 Range Extender Electrical Machine Electronics REME 5 Range extender ele...

Page 67: ...by the EME control unit Supply of the 12 V electrical system via the DC DC converter Control of the electrical machine engine speed torque using DC AC converter High voltage power management Contactin...

Page 68: ...C DC converter transfers electrical energy from the high voltage electrical system to the 12 V vehicle electrical system and assumes the function of the alternator in a conventional vehicle The DC DC...

Page 69: ...ble using energy from the 12 V vehicle electrical system The last operating mode of the DC DC converter is assumed during regular or quick shutdown of the high voltage system For the shutdown of the h...

Page 70: ...anation 1 Electrical machine 2 Connection to the 12 V vehicle electrical system 3 DC DC converter in the EME 4 Electrical machine electronics entirety 5 High voltage battery unit 6 EME control unit 7...

Page 71: ...ctrical machine are mainly made up of the bidirectional DC AC converter It is a pulse converter with a two pin DC voltage connection and a 3 phase AC voltage connection This DC AC converter can work a...

Page 72: ...DC AC converter Using the signals from the current sensor the EME control unit monitors the electrical power which is used in the power electronics and electrical machine and what torque the electric...

Page 73: ...tem IHKA control unit The externally available power cannot be at a high level it is restricted by the power network and the EME KLE Therefore the available power must be queried first before it can b...

Page 74: ...so that it will not suffer damage in the event of a short circuit at the output current limitation In order to protect the electric motor and the line against overloading the EME control unit monitors...

Page 75: ...n 1 Electrical machine electronics EME 2 PT CAN2 connection 3 Voltage supply 4 EME control unit 5 Output stage for parking lock module 6 Electric motor 7 Worm gear 8 First position sensor according to...

Page 76: ...trical vacuum pump should be switched on The function logic in the DSC control unit also takes into consideration a hysteresis so that the electrical vacuum pump is not constantly switched on and off...

Page 77: ...heless some vehicle characteristics were positively influenced by the installation of the high voltage battery unit in the Drive module of the I01 Thanks to the low installation location the center of...

Page 78: ...l data of the high voltage battery in the I01 Voltage 360 V nominal voltage 259 V 396 V voltage range Battery cells 96 battery cells in series each 3 75 V and 60 Ah Storable amount of energy 21 8 kWh...

Page 79: ...allation location Installation location of the high voltage battery unit Index Explanation 1 Vent hole 2 High voltage connection 3 High voltage battery unit 4 Frame Drive module 5 Refrigerant lines 6...

Page 80: ...safety rules must be observed 1 Disconnect the system from the power supply 2 Provide a safeguard to prevent unintentional restarting 3 Establish that the system is isolated from the power supply The...

Page 81: ...I01 High voltage Components 5 High voltage Battery Unit 75 5 1 3 System wiring diagram System wiring diagram of high voltage battery unit...

Page 82: ...unit firstly all preliminary work specified in the repair instructions diagnosis disconnecting from the power supply etc has to be performed Before the mounting bolts are slackened the special tool f...

Page 83: ...3 Mounting bolts 4 Potential compensation screw If the potential compensation screw can no longer be tightened to the required torque after a number of removal and installation procedures a new bore...

Page 84: ...located in the vehicle underbody for the best possible protection as a vehicle suffers the least amount of deformation in this area in the event of a crash In the event of a side collision the high v...

Page 85: ...cover of high voltage battery unit 2 High voltage component warning sticker 3 Warning sticker 4 Label with technical data 5 2 2 Electrical interfaces High voltage connection There is a two pin high vo...

Page 86: ...shed away and the contact established The plastic slide serves as the mechanical latch mechanism of the connector In addition it is also an element of a safety function If the high voltage cable is no...

Page 87: ...repair of the high voltage components is only allowed in a retail service center that has qualified and certified service technicians These technicians must have completed the ST1403b I01 High Voltage...

Page 88: ...Low voltage connection of the high voltage battery unit 6 Connection for refrigerant pressure line With the optional heat pump the actuating wires coming from the SME control unit for the combined ex...

Page 89: ...a refrigerant through the activation of the air conditioning function some of the water vapor from the air condenses This means small amounts of liquid water can form in the inside of the high voltag...

Page 90: ...voltage battery unit is essentially operational in the range of 40 C to 50 C These temperature limits however relate to the actual temperature of the cell not the ambient temperature In terms of temp...

Page 91: ...ire cooling system of the high voltage battery unit Index Explanation 1 Combined expansion and shutoff valve 2 Refrigerant lines for cooling of the high voltage battery unit 3 EKK 4 High voltage batte...

Page 92: ...electronics can activate and open the combined expansion and shutoff valve by applying voltage In this way refrigerant can flow to the high voltage battery expanding evaporating and cooling in the pro...

Page 93: ...refrigerant flows through them during cooling Heating Vice versa if the I01 was parked outside for example for several days at temperatures below 0 C it makes sense to heat the battery cells before de...

Page 94: ...required for charging In the vehicle a charging socket and power electronics are required for the voltage conversion Outside the vehicle a device which performs the protection and control functions i...

Page 95: ...dard The components for charging the I01 satisfy charging mode 2 connection to standard household socket with additional pilot line and charging mode 3 connection to fixed wallbox with pilot line The...

Page 96: ...ing interface Equipment basic version option US market LHD AC charging 7 4 kW Type 1 Standard Equipment Charging SA4U8 AC Fast Charging Combo AC charging 7 4 kW and DC charging 50 kW Combo 1 Optional...

Page 97: ...e 5 Charging plug 6 Charging socket at the vehicle Charging mode 1 i a w IEC61851 1 is NOT USED in the I01 due to a lack of communication between the vehicle and voltage supply IEC Charging mode 2 Occ...

Page 98: ...ion for connection to vehicle 5 Charging socket at the vehicle In the US market the plug connection between the charging cable and AC charging station is permanently attached to the charging station w...

Page 99: ...g parameters e g maximum current level between vehicle and EVSE The EVSE can either be integrated in the charging cable mobile solution or be an element of a fixed charging station also called wallbox...

Page 100: ...this EVSE to the AV voltage network the maximum current level is restricted for charging A product of this kind offered for the AC voltage network in Germany can be used up to a current level of 16 A...

Page 101: ...tations also called wallbox a distinction is made between AC charging stations and DC charging stations AC charging stations The connection of the AC charging stations to the AC voltage network can be...

Page 102: ...ore information regarding the charging cable refer to chapter 6 3 2 Charging Cable of this training manual In the US market a plug connection between the charging cable and AC charging station is perm...

Page 103: ...minor role large transformers and a rectifier can be installed there to use the full network power For this reason DC charging stations generally deliver a much higher charging power than AC charging...

Page 104: ...example for supply at AC voltage network in Germany 3680 W P U x I 230 V x 16 A The total time it takes to fully charge a discharged high voltage battery of the I01 storable energy 18 8 kW net would...

Page 105: ...I01 High voltage Components 6 Charging the High voltage Battery 99 6 2 1 Wiring diagram Wiring diagram for AC charging at 3 7 kW US market...

Page 106: ...or and status lighting 8 Range Extender Electrical Machine Electronics REME 9 Range extender electrical machine 10 Convenience charging electronics KLE 11 Charging socket at the vehicle 12 Electrical...

Page 107: ...e Electric Vehicle Supply Equipment are integrated in the charging cable This is called an In Cable box This charging cable for the I01 is always designed for single phase supply in line with the char...

Page 108: ...not permitted When the charging cable is connected do not fill the fuel tank and keep a safe distance from highly flammable materials Otherwise in the event of an improper connection or if the chargi...

Page 109: ...ng current in the vehicle to low 6 2 4 Charging socket at the vehicle The charging socket at the I01 is located precisely where the fuel filler neck is located in a conventional vehicle with a combust...

Page 110: ...electrically to ground in close proximity to the charging socket This ensures proper grounding A C shaped fiber optic conductor runs around the charging socket at the vehicle With this C shaped fiber...

Page 111: ...allation location of LIM The main tasks of the LIM are Communication with EVSE via pilot and proximity line Coordinating the charging procedure Activation of the LEDs for displaying the charging statu...

Page 112: ...lanation 1 Electric Vehicle Supply Equipment 2 Information whether the AC voltage network is available and the charging cable is correctly connected as well as the maximum available current level 3 El...

Page 113: ...ine The pilot line and the proximity line are realized as simple signal lines These signal lines are shielded and end at a connector in the charging interface module LIM Via the proximity line the con...

Page 114: ...o start the charging procedure immediately after connecting the charging cable or specify a time at which the charging procedure should start BMW i Remote app Charging the high voltage battery Index E...

Page 115: ...achine electronics fault temperature as well as the current level restricted by the AC voltage network and the charging cable Only when the communication between the vehicle LIM and Electric Vehicle S...

Page 116: ...e high voltage battery can be started Charging active The currently active charging procedure of the high voltage battery is displayed by flashing blue LEDs The flashing frequency is about 1 42 Hz Cha...

Page 117: ...hree times at a frequency of about 2 0 Hz and an interval of about 0 8 seconds between the three groups The LEDs for these displays are activated after the charging plug is connected or after unlockin...

Page 118: ...vides information on the status of the charging socket cover open closed In rest position i e when the charging socket cover is closed the microswitch is not actuated The microswitch is actuated when...

Page 119: ...rent flows The specifications for the output voltage and the output current come from the function High voltage power management in the EME control unit The values are calculated and adjusted by the E...

Page 120: ...version of the EVSE the time to fully charge a discharged high voltage battery in the I01 is cut by half when compared to AC charging with 3 7 kW standard equipment in European vehicles The same compo...

Page 121: ...I01 High voltage Components 6 Charging the High voltage Battery 115 6 3 1 Wiring diagram Wiring diagram for AC charging at 7 4 kW US market...

Page 122: ...n the proximity connection and the protective earth The resistance value specifies which maximum current level is allowed for the charging cable used dependent on the line cross section The assignment...

Page 123: ...rth 4 Connection for proximity line 5 Connection for phase L1 6 Connection for neutral conductor N 7 Mechanical guide connector housing 8 Button for the mechanical unlocking of the connector before re...

Page 124: ...odules completes this task These power electronics modules are controlled by a control unit which also bears the same name Convenience charging electronics KLE The convenience charging electronics is...

Page 125: ...oltage component Only qualified Service employees can work on the convenience charging electronics while observing the repair instructions Before working on the convenience charging electronics it is...

Page 126: ...High voltage cable AC from KLE to EME 6 KLE mounting potential compensation contact 7 High voltage cable DC from REME 8 Coolant line return 9 Convenience charging electronics KLE Low voltage connecti...

Page 127: ...he LIM enables the charging procedure via a signal on this line does the convenience charging electronics start the voltage conversion and thus the charging procedure The high voltage connectors of th...

Page 128: ...ts cannot be touched with fingers Range Extender Electrical Machine Electronics Two pin Direct current voltage 1 shielding per line Flat high voltage connector with mechanical lock Cover over the cont...

Page 129: ...side the so called inlet and a charging plug in which the two individual charging plugs are integrated for AC and DC charging Thanks to this universal connector system only one charging socket is req...

Page 130: ...I01 High voltage Components 6 Charging the High voltage Battery 124 6 4 1 Wiring diagrams Wiring diagram for combo charging at 7 4 kW US market...

Page 131: ...LIM 6 Electric motor for the connector fastener 7 Electric motor for the central locking system of the charging socket cover 8 Locator and status lighting 9 Charging socket at the vehicle 10 Convenien...

Page 132: ...ady described previously in this chapter Only the additional functions and tasks of the LIM for combo charging are described here A new tasks of the LIM is for example the activation of the switch con...

Page 133: ...t line is so low that the voltage evaluation for the EVSE is not affected In order to identify emergency charging the voltage value of terminal 30F is evaluated The evaluation circuit is located in th...

Page 134: ...9 Coolant line return 10 High voltage cable DC from the charging socket to the KLE 11 Convenience charging electronics KLE With the combo charging at 7 4 kW AC charging power the convenience charging...

Page 135: ...s also possible In this version of the convenience charging electronics two further switch contactors are housed which can shift through the direct current voltage of a DC charging station via the EME...

Page 136: ...e permitted to work on the designated high voltage components suitable qualifications compliance with the safety rules procedure following the repair instructions to the letter The diagnosis and repai...

Page 137: ...cured to the housing of the electrical machine using three screws The housing of the EKK is mechanically disconnected from the housing of the electrical machine thus improving the acoustic behavior As...

Page 138: ...nnect network bus ground and the 12 V voltage supply terminal 30 are integrated Special silencing in the pressure line provides for further acoustic comfort The heating and air conditioning is barely...

Page 139: ...ical power of up to 4 5 kW The maximum power is required for example at high ambient temperatures high interior temperatures high temperatures of the high voltage battery and low air flow of the cooli...

Page 140: ...outer disc with spiral profile and compressed and heated by the movement of the two discs with spiral profiles Principle of refrigerant compression After three revolutions the refrigerant drawn in is...

Page 141: ...rter DC AC converter in the EKK 9 Three phase current synchronous motor 10 Temperature sensor 11 Pressure sensor The high voltage contacts of the round high voltage connector for the EKK are protected...

Page 142: ...e designated high voltage components suitable qualifications compliance with the safety rules procedure following the repair instructions to the letter The diagnosis and repair of the high voltage com...

Page 143: ...on for coolant return 2 Sensor for temperature of the coolant at the output of the electric heating 3 Connection for potential compensation line 4 Signal connector low voltage connector 5 Connection f...

Page 144: ...d up in the electric heating and circulated by an electric coolant pump 20 W The warm coolant flows through the heat exchanger in the passenger compartment and emits the heat The warm air finally reac...

Page 145: ...e passenger compartment 3 Sensor for temperature of the coolant at the output of the electric heating 4 High voltage connection 5 Three heater coils The maximum electrical power of the electric heatin...

Page 146: ...ing control unit 5 High voltage battery 6 Electrical machine electronics 7 Bidirectional AC DC converter in the EME 8 Electrical machine 9 High voltage connector at electric heating 10 Hardware shutdo...

Page 147: ...e the contacts for the high voltage The contacts of the bridge in the high voltage connector are designed as leading contacts This means when removing the high voltage connector the contacts of the hi...

Page 148: ...lectronics Range Extender Digital Engine Electronics The W20 combustion engine is a 2 cylinder engine It is a small very smooth running and quiet gasoline engine which is connected mechanically to the...

Page 149: ...ical DC power at 4300 rpm and 330 V DC Efficiency about 94 Outer diameter about 300 mm Length about 115 mm Weight about 26 kg The range extender electrical machine is supplied by Valeo Installation lo...

Page 150: ...The rotor is located inside and is equipped with permanent magnets The stator is ring shaped and located outside around the rotor It is shaped with iron cores through the 3 phase coils If a 3 phase AC...

Page 151: ...components are still covered by a foam part This serves for the acoustic encapsulation of the range extender components and absorbs noises which the customer may find irritating The housing of the ran...

Page 152: ...se angle setting of the rotor must be known This is why there is also a rotor position sensor in the range extender electrical machine The rotor position sensor is secured at the stator of the range e...

Page 153: ...on 1 W20 Combustion engine 2 Mounting bolts for range extender electrical machine x6 3 Range extender electrical machine 4 Cover over the rotor position sensor The range extender electrical machine is...

Page 154: ...ared shaft for the power transmission Index Explanation 1 Range extender electrical machine 2 O ring seal 3 Grooved ball bearing 4 Sealing ring 5 Geared shaft The range extender electrical machine can...

Page 155: ...vious section High voltage connection at the range extender electrical machine Index Explanation 1 Range extender electrical machine 2 High voltage connection at the range extender electrical machine...

Page 156: ...an aluminium housing This housing accommodates the control unit and the bidirectional DC AC The range extender electrical machine electronics is a high voltage component Only Service employees who sat...

Page 157: ...I01 High voltage Components 10 REME 151 Installation location of the REME The REME is secured at the rear axle module on the right using three screws REME at rear axle module...

Page 158: ...combustion engine is reduced by a heat shield The heat shield is secured to the REME using three screws In order to remove the flat high voltage connector and the signal connector from the REME this h...

Page 159: ...ation line 5 Screw connection of the potential compensation screw at the rear axle module 6 Screw connection of the potential compensation screw at the REME 7 Range Extender Electrical Machine Electro...

Page 160: ...otential compensation line 4 Screw connection of the potential compensation screw at the REME 5 Range Extender Electrical Machine Electronics 6 Connection for signal connector 7 Connection for three p...

Page 161: ...SM for the signal for the quick shutdown of the high voltage system in the event of an accident of corresponding severity Wake up line Input and output of the circuit of the high voltage interlock loo...

Page 162: ...r electrical machine 4 3 phase high voltage connector at range extender electrical machine 5 3 phase high voltage connector at range extender electrical machine electronics The procedure for removing...

Page 163: ...ltage connector 5 Screws for securing the high voltage connector at the REME Two of the three screws are accessible and can be easily slackened To slacken the third screw the bridge of the high voltag...

Page 164: ...d REME 3 Range Extender Electrical Machine Electronics REME 4 Electrical machine electronics EME 5 Two pin high voltage cable between KLE 6 Convenience charging electronics KLE 7 Two pin high voltage...

Page 165: ...n line is secured using a screw connection 10 4 Structure and functions The range extender electrical machine electronics is made up internally of two subcomponents the bidirectional DC AC converter a...

Page 166: ...gine speed 5 Crash Safety Module ACSM 6 Signal for quick shutdown of the high voltage system in the event of an accident 7 Battery management electronics SME 8 Information about the state of charge of...

Page 167: ...rs the REME control unit monitors the electrical power which is used in the power electronics and the range extender electrical machine and what torque the range extender electrical machine generates...

Page 168: ...ng the electric motor components is necessary in the I01 To provide a complete overview the cooling system is shown below with the maximum equipment For vehicles with less equipment e g no range exten...

Page 169: ...I01 High voltage Components 11 Cooling the Electrical Machine Components 163 11 1 System overview System overview for cooling the drive components in the I01 maximum equipment...

Page 170: ...iator The components to be cooled are switched in the cooling circuit so that the maximum temperature levels required are observed A lower temperature is required for the electrical machine electronic...

Page 171: ...Electrical Digital Motor Electronics 5 Feed line 6 Electric coolant pump 80 W 7 Range extender electrical machine 8 Expansion tank in the cooling circuit of the combustion engine 9 Range Extender Elec...

Page 172: ...ing Loss of coolant e g by a leak Coolant air heat exchanger blocked Electric fan does not work or is restricted Coolant pump does not work Coolant lines or connections damaged Components to be cooled...

Page 173: ...occur to the convenience charging electronics the electrical machine the electrical machine electronics the range extender electrical machine or the range extender electrical machine electronics 11 3...

Page 174: ...oling of electric motor components Index Explanation 1 Body Domain Controller BDC 2 Signal terminal status 3 Temperature sensor in the electrical machine electronics 4 Signal temperature of the power...

Page 175: ...l machine electronics Component temperature of convenience charging electronics Component temperature of range extender electrical machine electronics Component temperature of range extender electrica...

Page 176: ...engine compartment lid or at the cooling module it is imperative terminal 15 is switched off While the high voltage battery is being charged the power electronics in the electrical machine electronics...

Page 177: ...have been disconnected If a high voltage plug connection has been disconnected the entire high voltage system is shut down automatically A square wave signal with alternating current direction is sen...

Page 178: ...I01 High voltage Components 12 Technical Safety Precautions 172 Main wiring diagram for high voltage interlock loop...

Page 179: ...der Electrical Machine Electronics REME 16 Evaluation circuit for test signal of the high voltage interlock loop in the electrical machine electronics 17 Electrical machine electronics EME 12 2 Starti...

Page 180: ...he positive terminal of the high voltage battery unit is closed The high voltage system is now fully operational If there is no fault in the high voltage system the entire starting of the high voltage...

Page 181: ...us signals The SME triggers the separation of the switch contactors in the high voltage battery In the case where communication via a data bus is faulty or not possible the switch off of the switch co...

Page 182: ...uring charging the SME control unit constantly identifies the state of charge already reached and monitors all sensor signals of the high voltage battery In order to ensure optimal progress of the cha...

Page 183: ...nents 12 Technical Safety Precautions 177 The cooling or refrigerant system must also be filled with coolant or refrigerant If the above mentioned preconditions are not satisfied the high voltage syst...

Page 184: ...h continuous Acceleration from 0 100 km h in 7 2 s Before a drive torque is applied the EDME must check whether the driving readiness is established The EDME also queries whether all subsystems of the...

Page 185: ...igh voltage battery very low Temperature of the high voltage battery extremely low or extremely high High voltage system deactivated Electric motor and climate control functions no longer work because...

Page 186: ...ery The relative SOC values are the values which are displayed to the driver in the instrument cluster or in the central information display In range A driving without power restriction and full funct...

Page 187: ...program with reduced consumption Climate control off blower output reduced windows are fog free Heating for passenger compartment Balance comfort range More economical program with reduced consumptio...

Page 188: ...15 7 absolute 11 SOC of the high voltage battery 75 relative 12 SOC of the high voltage battery 100 relative Up to a state of charge of the high voltage battery of 6 5 relative displayed SOC a I01 wit...

Page 189: ......

Page 190: ...Bayerische Motorenwerke Aktiengesellschaft Qualifizierung und Training R ntgenstra e 7 85716 Unterschlei heim Germany...

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