Table of Contents Closed Circuit Current Monitoring Subject Page Introduction .2 Purpose of the System .3 Power Supply Circuit .4 Power Module .5 Inputs.8 Outputs.9 Shut Down Protocol. 10 Closed-Circuit Current Monitoring Normal Sleep Mode.11 Storage Mode.14 Check Control Messages. 15 Workshop Hints Closed-Circuit Current Monitoring.16 Preconditions & General Observations.17 Closed-Circuit Current Monitoring Procedure.18 Diagnosing the Power Module with the DISplus/GTI.23 Battery Replacement Registration.29 Diagnostic Test Plans.32 Review Questions 33 Closed Circuit Current Monitoring Model: E65 - 745i / E66 - 745LI Production Date: 11/2001 - E65, 03/2002 - E66 Objectives of The Module After Completing this module, you will be able to: • Explain what the Power Module uses to calculate the optimum charge voltage. • Identify when the battery switch is left in the “OFF” position. • Perform the Battery Replacement Registration after replacing a battery. • Understand a normal Shut Down Protocol and identify a violation. • Identify 2 “visuals” that indicate the vehicle is entering sleep mode. • List the final Closed-Circuit Current draw on a “normal” vehicle. • Explain what Special Tool #90 88 6 612 310 is used for and demonstrate it’s use. 2 Closed Circuit Current Monitoring Purpose of The System This module describes the technical changes that have been made to the Power Module relevant to fault codes and diagnostic service procedures. You should be familiar with the basic operation covered in the E65 Complete Vehicle course (ST042). Additional informa¬ tion is now available for: • Closed circuit current monitoring • Check Control messages • Battery replacement The Power Module ensures that the battery charge level is maintained when the engine is running and when the vehicle is at rest. The Power Module is also responsible for main¬ taining the power supply (in the event of faults in the electrical system) to important vehicle systems by disconnecting lower priority circuits. Power Module Functions • Optimum charging. • Load-circuit peak reduction. • Shut-down of auxiliary consumer circuits in the event of low voltage. • Closed circuit current monitoring. • Distribution mode. • Automatic electrical system isolation. • Load cutout. • Electronic fuses. • Central battery voltage notification. • Rear window defogger output. • Interior lighting control. • Trunk lid and fuel filler flap control. • Data memory storage. • Emergency-mode functions. • Check Control messages. • Diagnosis. System Components • Power Supply circuit • Fuses • Power Module - Electronic battery master switch - High-current sockets - Inputs - Outputs connected to electronic battery master switch - Outputs not connected to electronic battery master switch - Electronic control unit 3 Closed Circuit Current Monitoring Power Supply Circuit The power supply for the general electrical system is controlled by the Power Module. The high amperage fuses in the engine compartment, the alternator and the starter motor are connected directly to the battery and not supplied by the Power Module. —1 i~»a- m~\ p ^iRSTg- _ _ [linn □ "X 110 Ah SBSR 420805 4 Closed Circuit Current Monitoring Power Module - Location and Construction The Power Module on the E65 is located on the right-hand side of the luggage compartment. 1. Cover plate 2. Electronics 3. Electronic Battery Master switch 4. Heat sink KL 30, KL 30B and KL 30U = High-Current Terminals Electronic Battery Master Switch The electronic battery master switch is made up of 4 MOS-FET output stages (S Bat) and connects the input terminal 30 with the outputs KL 30U and KL 30B on the Power Module. The following functions are controlled by means of the Power Module according to the posi¬ tion of the battery switch: • Storage mode • Electronic fuses • Closed circuit current monitoring • Automatic electrical system isolation High-Current Terminals (RADSOK®) New high-current terminals are used in the E65/E66. The high-current terminals are on the input terminal 30 and the outputs terminal 30U and terminal 30B. These contacts are capa¬ ble of carrying current peaks (short term) of 220 A. 5 Closed Circuit Current Monitoring Inputs/Outputs Battery K-CAN Periphery I K-CAN P Wake-up input CAS 1g from CAS Battery Switch Interior light switch External trunk release button Battery Temp. Sensor TOEHK 30U 30B HHS LM DME CAS DWA DWA_NS IR ZIG UFBD EC PDC RLS i fly sca 1 L > N UlS zu_ 0 J)TKL VA D VA K Terminal 30 outputs HHS=Rear window defogger. LM=Lamp Module. DME=ECU CAS=Car Access System DWA=Alarm C.U. DWA NS=Sirene IR=Not used in U.S. Terminal 15 outputs ZIG=Cig. lighter relay UFBD=Universal remote control. EC=Electrochromatic mirrors. PDC=Park Distance Control. Terminal R outputs RLS=Rain/Light Sensor (IB) Interior Lighting (VA-D) Consumer Isolation Circuit/Roof (VA-K) Consumer Isolation Circuit/Body SCA Soft Close Actuator (Trunk) ZV Central lock Actuator (trunk) TKL Central lock Actuator (Fuel door) 6 Closed Circuit Current Monitoring Inputs Terminal 30 The battery positive terminal is connected directly to the load input of the Power Module. Battery Switch The battery switch (BS) offers the vehicle owner and the service department the choice between the settings ON ("closed circuit current monitoring") and OFF ("storage mode"). It is located above the PM on the right hand side of the luggage compartment. ON OFF Interior Lighting Button This controls the interior lighting and is located on the front interior lighting unit. The possi¬ ble settings are "Automatic control", "On", "Off" and “Workshop mode” (hold for 3 sec¬ onds). Exterior Trunk Lid Release Button (TOEHK) This button is a direct input to the Power Module. The trunk lid is released by means of the button on the outside of the trunk lid. Trunk Lock Actuator Switch The switch in the trunk lock actuator is used to inform the Power Module as to the position of the lock actuator and to synchronize the SCA. it also controls the luggage compartment lighting, the monitoring of the alarm system and the trunk lid warning light. SCA Contact This input is used to signal the PM that the SCA has rotated 180° (used to switch off the electric motor). 15_w (wake-up) This is a redundant signal from the Car Access System which wakes up the Power Module. Battery Temperature Sensor Measures the temperature directly on the battery negative terminal. This information is used for the "optimum charging" function. The measuring range is -25°C to +75°C. K-CAN Periphery Enables communication with the vehicle network. 8 Closed Circuit Current Monitoring Outputs Connected to Electronic Battery Master Switch Terminal 30U Supplies the fuse box in the luggage compartment. Terminal 30B Supplies the fuse box in the glove compartment. Outputs Not Connected to Electronic Battery Master Switch The following outputs are supplied by the PM separately from the Electronic Battery Master Switch. • Rear window heater (HHS) • Light Module (LM) • Car Access System (CAS) • DME • Alarm system (DWA) • Emergency power siren (SINE) • Cigarette lighter (ZIG) • Electrochromatic mirrors (EC) • Park Distance Control (PDC) • Rain/light sensor (RLS) • Interior lighting (IB) • Central locking trunk lid drive (ZV) • Central locking, fuel filler flap (ZV) • Trunk lid Soft Close Motor (SCA) The advantages of this arrangement are: • The exterior lighting can remain on (for safety reasons) even if the Electronic Battery Mas¬ ter switch is off. • The alarm system is always armed. • No additional fuses and wiring for actuators in nearby locations. 9 Closed Circuit Current Monitoring Fuses The outputs for the rear window heater, KL R and KL 15, are not protected by convention¬ al fuses. They are supplied via a power transistor (MOS-FET) in the Power Module. By measuring the current and comparing it with stored threshold levels, the Power Module can detect a short circuit and disconnect the circuit if needed. The outputs for CAS, DWA and DME are protected by internal electronic fuses. Shut Down Protocol Shut-Down of Consumer Circuits (Sleep mode) To prevent battery discharge by consumer items mistakingly left on, the interior lighting cir¬ cuit (IB) and consumer circuits-roof zone (VA-D) are shut off 16 minutes after KL R is switched off. The consumer circuit-body (VA-K) remains on longer for the cigarette lighter relay, glovebox lighting, luggage compartment light and the telephone (recharging if plugged in). The VA-K is shut off 60 minutes after KL R is switched off. Shut-Down of Auxiliary Consumers In order to ensure that the car is capable of starting, the charge level (SoC-State of Charge) of the battery is monitored when the vehicle is at rest. The minimum battery SoC required to ensure that the car can be started again is a calculated value. The calculation takes into account the: • Battery temperature measured over last few days • Engine type • Capacity of the battery fitted (110Ah for the 745i). The SoC calculation is displayed as a percentage of battery capacity (a fully charged bat¬ tery is considered 80%). If the charge level of the battery gets close to that calculated min¬ imum level as a result of the operation of an auxiliary consumer unit, the Power Module instructs that circuit to switch off. Auxiliary consumer circuits are items such as the Control Display, DWA, LM, EGS and IHKA (rest function). There are two modes of operation when shutting down auxiliary consumer circuits: auxiliary consumers with KL R “ON” and auxiliary consumer with ignition off (KL 0). 10 Closed Circuit Current Monitoring Closed-Circuit Current Monitoring - Normal Sleep Mode • When the ignition is switched “OFF” (KL 0), the Busses go to sleep in 2 minutes. • After 16 minutes, the Power Module sends a signal for the consumer circuits-roof zone (VA-D) shut-down and briefly wakes the Busses. • VA-D is switched off and the Busses resume sleep mode. • After 60 minutes, the consumer circuit-body (VA-K) is switched off. The Power Module now assumes closed-circuit current monitoring mode: • Cyclic voltage measurement every 5 seconds, cyclic current measurement every 60 sec¬ onds. Note: If an operation is performed on the vehicle before 60 minutes has elapsed (central locking, trunk opened), the timer starts again from the beginning. • Once the 60 minute period has ended, the closed-circuit current is approximately 30 mA (max. 50 mA). • If the closed-circuit current exceeds 80 mA, the Power Module will monitor a 5 minute “waiting period” allowing the vehicle an opportunity to resume the normal 30 mA closed- circuit current. • If the excessive current remains after the 5 minute waiting period, a fault code with the current value is stored. The Power Module issues the "Shutdown Counter" message and after 90 seconds, the vehicle's electrical system is shut down (briefly isolated) by the Electronic Battery Master Switch. A second attempt is made and if excessive current draw is still present, the Shutdown Counter functions again after 90 seconds to isolate the electrical system. The Electronic Battery Master Switch is reconnected under the following conditions: • Change ignition from “OFF” to KL R or KL 15 • Toggling of the Battery Switch (switching back and forth twice within 2 seconds) • KL 15 wake-up line (from CAS) • External charge detection (> 13.2 V at the Power Module) • CAN message relating to activated, legally required electric loads (hazard warning lights) 11 Closed Circuit Current Monitoring When the signal “15w” from the CAS is detected, the Electronic Battery Master Switch is closed and the following Check Control message is displayed: Check Control Message displayed in KOMBI Message displayed in Control Display Cause High standby current! High standby current! Vehicle electrical accessories are drawing excessive passive-state current. Battery has been disconnected Please contact your BMW center. Excessive closed- circuit current draw MOM Closed-circuit current monitoring is automatically cancelled by a message from the Lamp Module that the hazard warning lights are active. When KL R is switched off, current monitoring is also immediately activated. Normal cur¬ rent load on the vehicle drops in stages according to the vehicle programming for sleep mode (see chart on the following page). If the monitored current is > 120 amps (even as a random spike) , the interior lighting, roof area consumers and body zone consumer circuits are immediately switched off. Reasons for Electronic Battery Master Switch Disconnection The reason for battery disconnection is stored together with the fault code in the Power Module fault memory. Several examples that may be stored are: • The battery was disconnected because a current > 120 Amps was measured after switching off KL R. Note: The current threshold was increased from 35 Amps to 120 Amps because all four power window motors can be operated simultaneously up to the end stop. • The battery was disconnected because an excessively high vehicle closed-circuit current was measured. • The battery was disconnected after a 3 week parking period. • The battery was disconnected by activation of Storage Mode with the Battery Switch. • The battery was disconnected because the battery capacity (SoC) dropped below the start limit with KL R switched on and KL 15 switched off. • The battery was disconnected because a short-circuit in KL 30 was detected. • The battery was disconnected by a DISplus/GTI diagnostic command. 12 Closed Circuit Current Monitoring 16 a Closed-Circuit Current Monitoring and Vehicle Sleep Mode 13 Closed Circuit Current Monitoring 25 seconds 16 minutes 60-70 minutes Storage Mode By switching “OFF” the battery switch, the Power Module goes into Storage Mode 30 minutes after terminal R switches off. — ““ _n_n_ “ OFF L_ _ _ _ _ _ _ _ KT-8288 Before disconnecting, the PM sends out the "Shutdown" signal. After a further 90 seconds the shut down is completed. If the ignition switch is turned to KL R or KL15, a Check Control message is issued which informs the driver that the vehicle is in Storage Mode. The following CC message appears: Check Control Message Message displayed in Cause displayed in KOMBI Control Display Battery switch OFF Battery switch OFF! Battery switch left in Re-set battery switch in luggage OFF position, compartment to ON, refer to owners manual. When the signal “15w” or change-over of the battery switch to "closed-circuit current mon¬ itoring" is detected, the Electronic Battery Master Switch is closed. The vehicle can still be started and driven in storage mode. All systems remain functional. The CC message remains active. When KL R “Off" is active, disconnection is carried out after 30 minutes (as explained above). Note: If the battery switch is detected as defective, closed-circuit current monitoring will be activated. If no function of any kind is activated over a period of 3 weeks, the battery is disconnected from the vehicle's electrical system to prevent battery discharge. This function is indepen¬ dent of the position of the battery switch. Electronic Fuse If a short circuit current of over 250 A is detected, the Electronic Battery Master Switch is opened. When the wake-up signal “15w” from the CAS is detected, then an attempt is made to close the Electronic Battery Master Switch again. This procedure is repeated continually until the short circuit has been eliminated. 14 Closed Circuit Current Monitoring Check Control Messages The following are Power Module relevant messages: Check Control Message Message displayed in Cause displayed in KOMBI Control Display Battery switch OFF! Battery switch left in Re-set battery switch in luggage OFF position, compartment to ON, refer to owners manual. High standby current! Excessive closed- Vehicle electrical accessories circuit current draw, are drawing excessive passive-state current. Battery has been disconnected Please contact your BMW center. Recharge Battery! Recharge battery! Battery discharged Battery heavily discharged. Charge by driving for longer period or by using external charger. Battery will be disconnected soon. Power module in emergency ! Power module in operating mode. Electrical emergency mode power supply limited. Please contact the nearest BMW center. Power Module failure! Power module failure! Power module alive Automatic monitoring of signal missing over ■ battery charge level failure. bus line. Please contact the nearest BMW center. Notes: High standby current! Battery Switch OFF! 15 Closed Circuit Current Monitoring Workshop Hints Closed Circuit Current Monitoring For The E65/E66 Electrical System In the event that an E65/E66 vehicle has a battery draw and/or the Power Module has faults stored in memory relative to closed circuit current monitoring, the following is provided to assist you in diagnosis. Increased closed-circuit currents may occur permanently or occur intermittently, and cause the battery to discharge prematurely. The increase in closed circuit current may be caused by a faulty control module, or by the installation of a non-approved accessory. In a situation where a vehicle has compalints due to a discharged battery, for diagnostic purposes it is important not to disconnect the battery. This is because a control module will be reset if the battery is disconnected. Following a reset, the faulty control module may start functioning correctly again, making accurate diagnosis impossible. To correctly measure closed-circuit current, measurement adapter Special Tool P/N 90 88 6 612 300 should be used. This tool provides a bridge to ground, before the negative bat¬ tery terminal is disconnected, and this prevents the control modules from being reset. The additional use of MoDiC adapter Special Tool P/N 90 88 6 612 310 provides a method for current measurements over an extended period of time. This procedure should be followed after you have reviewed the Power Module “Principle of Operation” in the beginning of this module. Tools Required: • 50 amp inductive probe for DISplus or MFK1 for the MoDIC/GTI. • BMW closed circuit current measuring tool # 61 2 300 (4. in diagram). • Digital Multimeter capable of measuring up to 15 Amps. • MoDIC adapter #61 2 310 for recording draws up to 72 hours (3. in diagram). 16 Closed Ciroiut Current Monitoring Preconditions: • First, read and understand SIB # 61 08 00 • Charge the vehicle battery with a BMW recommended (Deutronic) battery charger to obtain a minimum of 12.6 Volts. The battery charger must be disconnected prior to any draw testing. • Vehicle charging system must be operating correctly. • Ceck for faults and correct any faults that are present. • Have a copy of the bus chart ready for reference. Understand the basics in order to “Divide and Conquer” the bus network. • Review the power supply wiring diagram to understand the three (3) separate routes that the B+ potential can travel. The B+ lead that feeds the IVM/ECM, starter and generator. This lead has a junction in the luggage compartment and supplies the aluminum ribbon cable to the front of the vehicle. The second is the feed from the Power Module 30 B to the front fuse panel in the glove box. Moving the current probe to each individual cable will isolate which circuit has the current draw(s). • Review the Vehicle Sleep Mode shut down protocol chart (page 13) to assist with com¬ parisons when diagnosing a faulted vehicle. Please Review the Following General Observations: 1. After swithcing the ignition “OFF”, the CAS light remains “ON” for approximately 2 min¬ utes. When the CAS LED goes out, this indicates that the Bus network is sleeping. At this time the current measurement should not be > 800 mA (.8 A). 2. After approximately 16 minutes the CAS led illuminates for approximately 30 seconds (Bus network is awake). After the CAS LED goes out (Bus network is sleeping), the BZM seat switch lights (left and right) will turn off. At this time the Power Module circuit VA-D roof consumers shut down (hint - leave a map light on as a visual). The current draw is approximately 200 mA (.2 A) at this time. 3. The remaining time until the vehicle is in “sleep mode” will occur in approximately 44 minutes (vehicle dependent). The total time for sleep mode could take up to 70 min¬ utes. 17 Closed Ciroiut Current Monitoring 4. The final closed circuit current draw should be approximately 30 mA (.030 A) or less (normal peaks last for approx. 20 seconds each). These normal peaks are a result of the Instrument Cluster performimg a temperature status check (deminishes in frequency as time goes on). 5. Always allow the vehicle to go into the sleep mode naturally. Do not use the DISplus/GT 1 test module to expedite shut down on the initial diagnosis. This test module can be used after the conformation of failure has occurred and additional testing is required. This will help in speeding up the subsequent diagnosis. Closed Circuit Current Monitoring Procedure: The following instructions can be supplemented with the HI document in DIS under Power supply Diagnostic Test Plan, entitled "Procedure in event of closed circuit current faults”. There are examples of closed-circuit current violations with additional diagnostic hints. 1. With the DISplus/GTI, interrogate all control modules with a short test. Correct all faults before proceding with closed circuit diagnosis. This includes reviewing diagnostic queries for the Power Module to analyze reasons for battery disconnects, battery SOC, battery history and basic charging operation. 2. Disconnect battery charger from the vehicle (remove clamps). 3. Open the trunk lid and secure the latch mechanism (as if the trunk lid was closed). 4. Open hood and lift up on the hood pin switch (service position). 5. To prepare for fuse access, open the glove box door and disable the glovebox light. This will avoid awakening the Power Module later. 6. Hook up current monitoring tools following this progression: If using the DISpius: - 50 amp inductive clamp around the B- cable from the battery to chassis ground. Access the BMW Test system “Multimeter screen" , and select the “Current 50A” set¬ ting and “MIN/MAX”. Prefered - MoDIC/GTI (when function is available on GT1) - 50 amp inductive clamp around the B- cable from the battery to chassis ground. - MFK1 connected to Special Tools #61 2 300 and #61 2 310 (as shown on page 16). Follow MoDIC setup instructions per SIB # 61 08 00 (do not plug into MoDIC yet, just have connections ready), do not disconnect the chassis ground at this time. This tool can only handle a current of 10 amps or less and will fail until the vehicle current is safely below this value. 18 Closed Ciroiut Current Monitoring 7. Shut off ignition “KL 0”, remove the remote key from vehicle. Open both front doors and secure rotatory latch (as if the doors were closed), Use a suitable tool and not your fin¬ ger! Be careful not to catch your fingers in the latch, the vehicle may be equipped with Soft Close Automatic (SCA). Activate the remote locking “twice” (to disable the FIS sen¬ sor) and begin to watch for Bus power down. 8. After the CAS LED goes out (approx. 2 minutes), the current draw should not be > 800 mA. The BZM lights will remain on. 9. After approximately 16 minutes, the CAS LED will illuminate. The current draw will spike to approximately 8 - 9 A for 30 seconds. Then the CAS and BZM lights go out and the current draw will be approximately 200 mA for 60 -70 minutes. Unplug the 50 amp clamp lead from the MoDIC and plug in the MFK1 lead, it is now safe to remove the chassis ground and the draw trace will begin if the MoDIC/GTI is used. At the 60 -70 minute point (sleep mode), if the closed-circuit current draw is > 30 mA, normal procedures of pulling fuses and disconnecting components will be necessary (as outlined below). Remember to divide and conquer the circuits with the help of the ETM. If the closed-circuit current draw remains higher than 30 mA after 60 minutes or never drops down to less than 30 mA proceed as follows (the MoDIC/GTI- when function is avail¬ able on GT1, must be used at this point to establish a draw trace): 10. Remove Fuse 5 from the front fuse box behind the glove compartment (Fuse 5 also powers the BZM, the seat switch lights will go out). Wait 2 minutes (allows CAS to reset) and recheck draw. If draw drops down to below 30 ma reinstall Fuse 5 and disconnect 1 MOST bus con¬ sumer at a time (Control Display last - it is the gateway) and install optic jumper (made from parts, available in EPC) wait 2 minutes between each disconnection (allows CAS to reset). 11. If draw is still present after Fuse 5 removal, remove Fuse 15 to ZGM from front fuse box, this isolates the Byteflight Bus from PT-CAN Bus. If draw drops down, then disconnect SIM module behind glove box and reinstall Fuse 15. If draw drops after SIM removal then draw is from Byteflight and isolate which Byte- flight module is causing draw. If draw does not drop after SIM removal, the draw is com¬ ing from PT-CAN bus. Disconnect each PT-CAN Bus module until draw is gone. 12. If removing Fuse 5 and or Fuse 15 do not drop draw below 30 mA, then draw is from K-CAN S and or K-CAN P modules. Disconnect one CAN consumer at a time until draw is gone. Note: Please refer to Bus Chart on page 20. 19 Closed Circiut Current Monitoring .£2 t3 m m £ +; ... ro ro o „ v £ co g o > ° a 05 °5_ « £ f 4 2 £ ^NO) DC i: QD C/5 O s < o I * Q. Z < o ■ * 20 Closed Ciroiut Current Monitoring Disconnect the SIM Module to isolate the Byteflight Bus. Closed Circuit Current Monitoring Flow Chart Key Off = KL”0”, Wait 2 min. is the CAS LED Out? YES Wait for 16 minutes. Is the BZM light out? YES NO PM is shutting BZM down wait full light not out. 60 min. and PM shut down monitor current is not draw. occurring (circuit VA-D). Is current < 30 mA? Review PM operation. Use > / X Component Activation to YES NO check possible OK >30 MA PM faults. Isolate current draw. Remember to use 30U/30B cable to help determine draw (front to rear). Check individual circuits that are isolated from 30U/30B (LM, DWA, alt, aux. fan, etc). NO Remove Fuse #15 powering ZGM. Wait 2 Minutes for CAS light to go out. Is CAS light out? YES Fault is in ByteFlight or PT-CAN Bus awakening all Busses. Reinstall Fuse #15 and unplug SIM, wait 2 minutes. NO Reinstall Fuse #15. Remove Fuse #5 wait 2 min. & watch current draw. Is the light out? YES NO Fault is in ISIS Fault is in the circuit. PT-CAN. Isolate by Isolate by unplugging unplugging each Satellite each module and waiting 2 min. between until isolated. each unplug. Wait 2 min. between each Recheck draw after 1 hour to validate. Use PM Service Function Shut Down to validate instead of waiting full 60 miniutes module unplug Note: BZM light will not function with Fuse #5 out, however CAS light will function. CAS light out? YES NO Most Bus Reinstall concern. Fuse #5. Unplug Remove Control Modules K CAN-S with 2 min. Low/Pligh wait between, wires from until isolated. CAS XI0318. Term 13 (green) Term 14 (green/orange) Is light out in 2 min? YES NO Isolate Isolate K-CAN P K-CAN S components components as outlined as outlined in previous in previous steps. steps. 21 Closed Circiut Current Monitoring Sleep Mode with PT-CAN Bus Consumer (example) When the closed-circuit current draw remains higher than 30 mA after 60 minutes or never drops down < 30 mA, the MoDIC/GTI (when function is available on GT1) used at this point establishes a draw trace. In this example, a consumer stays awake after the 60 -70 minutes. From the peaks you can observe that the closed-circuit current draw is not normal. By removing Fuse #15 to ZGM (in front fuse box), the Byteflight and PT-CAN Bus circuits are isolated and the closed-circuit current draw decreases to a normal value. After disconnecting SIM module and reinstalling fuse #15, the draw still exists indicating that it is from PT-CAN bus. By disconnecting each PT-CAN Bus module (one at a time), the draw decreased after the Electro-mechanical Parking Brake Control Module (EMF) was unplugged. This component was staying awake and in addition, awoke the entire Bus network. 22 Closed Ciroiut Current Monitoring Diagnosing the Power Module with the DISplus/GTI After the initial power down protocol in which the vehicle enters “sleep mode” naturally and excessive closed-circuit current draws are present, the DISplus/GTI can be used to expe¬ dite sleep mode for further diagnosis. This procedure is found under: Service Functions - Body - Voltage and current monitoring. • Select , and . • Highlight the Test Module and press the green to the right. The following preconditions must be followed for a successful Power Down: • DISplus/GTI connected • Battery Switch set to “ON” • KLR “OFF”, but vehicle must not have gone to sleep yet • Remove key • Battery voltage must be at least 12.5 V and battery charger must be disconnect¬ ed from vehicle • This screen prompts you to select to send the Power Down command. |H [Ilspgglte ©siM:<§ai) (Complete vehicle p Component and signal information Signal information Service functions Maintenance Drive Chassis Body Instrument cluster Heating/air-conditioning systen Wipe/wash functions Remote control/vehicle key T elecommunication ISIS control modules Headlight cleaning system Auxiliary and independent heatir] MOST network E feCaiQ anil aulQuiljilaiirBifaii Matte atesipmafe Power down command Note: After the Power Down command is sent, disconnect the OBD diagnostic connector. The Power Down mode is terminated when a Bus is woken. 23 Closed Ciroiut Current Monitoring The inputs/outputs that are part of the Power Module can be diagnosed by Test Modules or status check by the Control Unit Functions of the Diagnosis Program. The outputs can be activated by Component Activation and the power consumption displayed. All electronic fuses and the Electronic Battery Master Switch are monitored for short cir¬ cuits/circuit breaks. In the event of a fault, an entry is made in the Power Module fault mem¬ ory and if appropriate, a Check Control message is initiated. The “Status” of the Power Module and monitored circuits/components can prove to be very helpful in diagnosing faults and provide an overall state of vehicle “electrical power man¬ agement”. • From the DISplus/GTI main menu (after a short test was completed), select . • Select and highlight Part Functions of the status to be displayed. Some Power Module status examples to consider are: • Number of battery disconnections • Closed-circuit current counter • Temperature • Wake terminal 15 • Battery switch, switch contact 2 • Battery switch, switch contact 1 EfaifaBlunffla ©ffiitell ornR taste® Rm&fais AMP Amplifier AVT Antenna tuner ARS Dynamic Drive ASK Audio system controler SMBF Scat module, passenger BZM Control center, center conso CAS Car Access System CDC Audio CD Changer |x CIM Chassis Integration Modules DSC Stability Control DSC5.7 DWA antitheft alarm system SINE Siren and tilt sensor CON Controller EGS transmission control -Activate outputs, rear lid •Activate outputs, fuel-filler flap Diagnosis requests Load/consumer priorities_ -Pov/cr module, output -Reason for disconnecting battery -Alternator -Battery -Battery statistic -Battery history -Rear lid Interior lights Rear-window defroster Lt. lAul'A'i' Number of battery disconnections Closed-circuit current counter Temperature Wake terminal 15 Battery switch, switch contact 2 Battery switch, switch contact 1 1 61 22 On Closed Open Notes: 24 Closed Ciroiut Current Monitoring • By selecting , output loads and con sumers with the amperage val¬ ues are displayed. This includes the electrical load for the roof and body zone previ¬ ously mentioned. These functions can be activated/deactivated found in: "Activate outputs, elec¬ trical loads”. This provides you with information about what circuit of the Power Module is experiencing current draw, normal or excessive. • By selecting , this will display why the Power Module switched of the Electronic Battery Master Switch. Examples of why the Power Module switched off the Electronic Battery Master Switch to disconnect the battery are: • Excessive current was measured after switching off KL R. • Excessively high vehicle closed-circuit current was measured. • A short-circuit in KL 30 was detected. • After a 3 week parking period (Stand-time limitation). • The battery capacity (SoC) dropped below the Start limit (threatened). • By a DISplus/GTI diagnostic command. 3Am^i:rdTg _ AMP Amplifier AVT Antenna tuner ARS Dynamic Drive ASK Audio system controller SMBF Seat module, passenger BZM Control center, center conso | CAS Car Access System CDC Audio CD Changer x CIM Chassis Integration Modules DSC Stability Control DSC5.7 DWA antitheft alarm system SINE Siren and tilt sensor CON Controller EGS transmission control -Activate outputs, rear lid -Activate outputs, fuel-filler flap Diagnosis requests - Load/consumer priorities -Power module -Reason for disconnecting battery -Alternator -Battery -Battery statistic -Batten/ history -Rear lid -Interior lights -Rear-window defroster t~lL VTLmvTnd bi | - - v ' < jAv.TjIL A- _ ■ _. r. -, ■-V. — ;jj. j i_ Current, light module Current, electrical load, body Current, electrical load, roof Current, engine compartment Current, terminal R Current, terminal 30 Current, terminal 15 Output, light module Output, electrical load, body ©§i®M) raafs fametaB ; IxfliiiKai ii-ite _ AMP Amplifier AVT Antenna tuner ARS Dynamic Drive ASK Audio system controller SMBF Seat module, passenger BZM Control center, center conso CAS Car Access System CDC Audio CD Changer j x CIM Chassis Integration Modules DSC Stability Control DSC5.7 DWA antitheft alarm system SINE Siren and tilt sensor CON Controler EGS transmission control -Activate outputs, rear lid -Activate outputs, fuel-filler flap Diagnosis requests - Load/consumer priorities -Power module -Power module, output -Alternator -Battery -Battery statistic -Battery history -Rear lid -Interior lights -Rear-window defroster I bnopL’ ater fta 1 ‘M [ respite Cun-ent after tm. R deactivation too high Closed-circuit current too high Short circuit detected Stand-time limitation reached Startability threatened Term. 30 deactivated by diagnosis Not disconnected Not disconnected Not disconnected Not disconnected Disconnected Not disconnected 25 Closed Ciroiut Current Monitoring • By selecting , this will display the charging output that the Power Module desires and receives from the Alter¬ nator. The Power Module regulates the charge level to the battery based on: Optimum Charging The battery voltage can fluctuate between 14.0 V and 15.5 V. The optimum charge voltage is set according to the charge level of the battery, the battery temperature and the status of the external lights (higher charging voltage with lights off). The maximum setting is 16 V. Temperature-Dependent Battery Charging Voltage By using a charging characteristic map stored in the Power Module, the charge voltage of the alternator is adjusted according to the battery temperature. The Power Module detects the temperature of the battery and places the instruction "Increase charge voltage" on the K-CAN Periphery. The CAS passes the message on to the K-CAN System bus. The ZGM receives the message. Performing its function as a "gateway control unit", it passes the message on to the PT-CAN. The ECM module receives the request to increase the charge voltage over the PT-CAN. The alternator then receives the request to increase the charge voltage via the BSD lead (Bit Serial Data interface). The electronic evaluation unit in the alternator then adjusts the charge voltage accordingly. If the temperature sensor is defective then the charging voltage will be fixed at 14.3 V. Increasing Idle Speed to Improve Battery Charging In order to drain as little energy as possible from the battery during freezing weather (below 34°F) the engine idle speed may be increased. This ensures that the battery charge level is kept high. If the charge level falls below the cal¬ culated minimum level for starting, the engine idle speed is increased to 750 rpm. The calculation of the minimum level for starting takes in account the temperature and the condition/age of the battery. aw CQfcnfarlirTnffla AMP Amplifier AVT Antenna tuner APS Dynamic Drive ASK Audio system controller SMBF Seat module, passenger BZM Control center, center conso CAS Car Access System CDC Audio CD Changer |x CIM Chassis Integration Modules DSC Stability Control DSC5.7 DWA antitheft alarm system SINE Siren and tilt sensor CON Controlcr EGS transmission control Current, alternator Voltage, alternator, desired Voltage, alternator, specification TuviTiTT; [-Activate outputs, rear lid Activate outputs, fuel-filler flap [Diagnosis requests |- Load/consumer priorities Power module -Power module, output -Reason for disconnecting battery -Battery -Battery statistic -Battery history -Rear lid -Interior lights -Rear-window defroster tafeEa afcarEfisE, Mrasl 26 Closed Ciroiut Current Monitoring • By selecting , this will display the battery “state of health” according to the Power Module’s calculation. The relationship of charge vs: dis¬ charge can be seen here. This is helpful for determining a sulfated battery. Battery Charge Level Detection The Power Module knows what the charge level of the battery is at any time by calculating the battery current when the vehicle is being driven and measuring the discharge current. When the vehicle is not in use, the charge level is re-calculated and updated by measuring the closed circuit battery voltage. If the vehicle battery is replaced it must be registered with the Power Module so that the stored values can be deleted and a new calculation started. Central Battery Voltage Notification The Power Module continuously measures the battery voltage. This information is made available to all other control units via the Bus link. This can be used, for example, to enable continuous running of the sliding/tilting sunroof regardless of battery voltage. Central battery voltage notification eliminates the need for individual measurement of bat¬ tery voltage by each control module. Data Memory The Power Module data memory stores electrical system activity (data) relevant to the vehi¬ cle. That information provides a status read-out of the battery load and life. The data mem¬ ory will be used in future to obtain a load profile of the battery in normal operation that will be analyzed for Condition Based Service. Battery Temperature Sensor In the event of a defective sensor, a short circuit or an implausible value, the substitute value of 20 °C is assumed. This corresponds to a fixed charge voltage of 14.3 V at the battery. Battery capacity (SoC) is calculated using the substitute value. MW ttpxaSll§ MMomilllllEUlMB C%iaffiaB8 1 AMP Amplifier -Activate outputs, rear lid AVT Antenna tuner -Activate outputs, fuel-filler flap tOiEtfav* ARS Dynamic Drive Diagnosis requests _ _ ASK Audio system controller - Load/consumcr priorities !JMrcssS5B SMBF Seat module, passenger -Power module BZM Control center, center conso -Power module, output CAS Car Access System -Reason for disconnecting battery CDC Audio CD Changer -Alternator x CIM Chassis Integration Modules =0S0SI» DSC Stability Control DSC5.7 -Battery statistic DWA antitheft alarm system -Battery history SINE Siren and tilt sensor -Rear lid CON Controller -Interior lights EGS transmission control -Rear-v/indov/ defroster Temperature 17 •c 3 Current -14.6 A Voltage 12.3 V Charge state 67.1 Ah Charge, total 0 Ah Discharge, total 22 Ah 27 Closed Ciroiut Current Monitoring • By selecting , this will display by day (up to 9 days) in what “state of charge” the battery is and was, accord¬ ing to the Power Module’s cal¬ culation. In addition, the vehicle distance (in km) is displayed that is applied to the present battery. When the battery is replaced, a reset must be registered to start this calculation as it applies to the replacement battery. &W8 SfegiMete ©SfflW AMP Amplifier AVT Antenna tuner ARS Dynamic Drive ASK Audio system controller SMBF Seat module, passenger BZM Control center, center conso CAS Car Access System CDC Audio CD Changer x CIM Chassis Integration Modules DSC Stability Control DSC5.7 DWA antitheft alarm system SINE Siren and tilt sensor CON Controller EGS transmission control Activate outputs, rear lid Activate outputs, fuel-filler flap Diagnosis requests - Load/consumer priorities -Power module -Power module, output -Reason for disconnecting batten/ -Alternator -Battery Battery statistic tWrnmrn _ •Rear lid •Interioi lights Rear-window defroster Kilometer reading 5 days ago Kilometer reading 7 days ago Kilometer reading 8 days ago Kilometer reading 9 days ago Charge state, Charge state Charge state Charge state Charge state Charge state Charge state Charge state Charge state current 1 day ago 2 days ago 3 days ago 4 days ago 5 days ago 6 days ago 7 days ago 8 days ago ©aiMIMfe_ Irtiffirifriiaa AMP Amplifier -Activate outputs, rear lid [LsE6lkBiaawdtei«HS . 2 AVT Antenna timer -Activate outputs, fuel-filler flap tenl fera-IHKJ*sa**i®ni0 ARS Dynamic Drive Diagnosis requests ASK Audio system controller - Load/consumer priorities SMBF Seat module, passenger -Power module mm ! BZM Control center, center conso -Power module, output fatp CAS Car Access System -Reason for disconnecting batten/ mm wMee | CDC Audio CD Changer -Alternator 5 x CIM Chassis Integration Modules -Battery igkflSSD' KSEHlffi: 1 A* SEN DSC Stability Control DSC5.7 -Battery statistic Stem®! motar * Aw»» DWA antitheft alarm system ttasSir siita f. !®k SINE Siren and tilt sensor -Rear lid KHanrcfer raidBaz i ism see CON Controller -Interior lights ffflTffirefcp isulfcg g EGS transmission control -Rear-v/indow defroster itemter majlhB B ffiae sees U| IXt*j*rits ami isatlte Last battery change 1968 km 1 Second-from-last battery change 0 km TNrd-from-last battery change 0 km Fourth-from-last battery change 0 km Fifth-from-last battery change 0 km Sixth-from-last battery change 0 km Seventh-from-last battery change 0 km Kilometer reading, current 1968 km Kilometer reading 1 day ago 524280 km 3 Battery Replacement Registration (Must be performed when a battery is replaced) This Service Function informs the Power Module that the battery has been replaced. It completes the following operations: • Battery capacity is set to a value that is dependent on seasonal temperature. • The current odometer reading is stored. • Previously stored battery statistics (current, voltage, battery charge level) are deleted. • Previously stored temperature statistics are deleted. 29 Closed Ciroiut Current Monitoring When the "Register battery replacement" is requested, the state of charge (SoC) of the bat¬ tery is not set to 80%, but to a value that is dependent on the seasonal temperature. The seasonal temperature is an averaged time based value (over the last few days) for the battery SoC that is required for a successful starting procedure. The battery SoC value is set 28% above the SoC calculated from the seasonal tempera¬ ture. The following examples for the SoC after battery replacement are: Seasonal Temperature SoC Value -25 °C 98% -10°C 68% 0 °C 66% 10 °C 63% 20 °C 61% 30 °C 58% The SoC is maintained at these values until the ignition is switched “OFF” for > 2 hours. The SoC is redetermined during the closed-circuit voltage measurement (conducted after 2 hours) and then calculated based on the battery current. Note: Central Locking, door changes (open/closed) and interior light status changes must not occur during this time because the timer will restart. Procedure for Battery Replacement Registration This procedure is found under: Service Functions - Body - Voltage and current monitoring. • Select , . • Highlight the Test Module and press the green to the right. - i&Wii-LaiLB StomSfliE *i(to^sn3aEoixsaliafla!I mu - rcn n. Complete vehicle Component and signal information Signal information Service functions Maintenance Drive Chassis Body Instrument cluster Heatingrair-conditioning systeir Wipe/wasti functions Remote control/vehide key Telecommunication ISIS control modules Headlight cleaning system Auxiliary and independent hcatii MOST network - Hit _ “ hands’ SdStawratasnratf 'Ji Activate sleep mode jRegister battery replacement 30 Closed Ciroiut Current Monitoring The screen prompts you to select: 1. Display battery replacement (as described on page 29) 2. Register battery replacement 3. Terminate test module Select #2. to the right. This screen prompts you to: 1. Enter battery replacement 2. Cancel Note: The battery replacement will be entered in the Power Module in the next test step. Warning! The entry cannot be reversed. Again, this Service Function informs the Power Module that the battery has been replaced and completes the following operations: • Battery capacity is set to a value that is dependent on seasonal temperature. • The current odometer reading is stored. • Previously stored battery statistics (current, voltage, battery charge level) are deleted. • Previously stored temperature statistics are deleted. 31 Closed Ciroiut Current Monitoring Diagnostic Test Plans Based on fault codes, additional diagnostic Test Plans can be found under: Complete Vehicle - Body - Power Supply. Test plans are available for: 1. Voltage/current monitoring 2. Battery 3. Alternator mm Hgpsai ©■xaMfioiB Complete vehicle Ci Drive Chassis Body General vehicle electrical systen Charge control Load-side peak consumption rcdi Electrical system disconnection Electronic battery master sv/itch Load deactivation, electronic fuse Operation Display and Information Functio Audio, video, navigation (MOS1 Lights Heating and air conditioning fun Locking and security functions Safety functions Signal and warning functions Seats Wipe and wash functions Telecommunication Bus functions Mirror Auxiliary and independent heatii Component and signal information Signal information Service functions Battery condition Closed-circuit current performanc Battery Alternator m I Voltage/currcnt monitoring When you select , the Test modules (based on the status dis¬ plays previously covered) available are: Charge control - tests the Power Module’s management of battery charging. Load-side peak consumption reduction - tests the Power Module’s commands and rea¬ sons to activate the prioritized shutdown of electrical consumers. Electrical system disconnection/Electronic battery master switch - tests the Power Module’s commands and reasons to reduce power consumption and disconnect exces¬ sive closed-circiut power consumers based on battery SoC and time. Load deactivation, electronic fuse - tests the Power Module’s commands and reasons to open the electronic master switch if a high short circuit current is detected. Battery condition - tests the Power Module’s interpretation of the overall battery life. Closed-circuit current performance - tests closed-circuit current draws with additional Help Information (HI) documents showing examples of violations that prevent normal power down protocols and procedures to diagnose closed-circuit current faults. Notes: 32 Closed Ciroiut Current Monitoring Review Questions 1. What information does the Power Module use to calculate the optimum charge voltage? 2. How would the driver of the vehicle know that the battery switch was in the “OFF” position? 3. What must be performed to the Power Module after replacing a battery? 4. What operations are a result of question 3? 5. During a normal Shut Down Protocol, what consumers are shut off after 60 minutes? 6. What 2 “visuals” indicate to you that the vehicle is continuing to enter sleep mode after the 16 minute period? 7. What should the final Closed-Circuit Current draw be on a “normal” vehicle? mA 8. What Bus circuit(s) are isolated when Fuse #15 is removed? 9. What fixed charge voltage would you expexct to measure if the Battery Temperature Sensor was defective? V 10. What is Special Tool #90 88 6 612 310 used for and what does it provide? 33 Closed Circiut Current Monitoring