BMW 3: High-voltage cables
The high-voltage cables connect the high-voltage components and are identified by orange cable sleeves. The manufacturers of hybrid cars have agreed on a uniform identification of the high-voltage cable with the orange warning color. An overview of the high-voltage cables used in the G20 PHEV is provided here.
G20 PHEV, high-voltage components and high-voltage cables
- Electric Motor Electronics (EME)
- High-voltage battery unit
- Convenience charging electronics (KLE)
- Charging socket
- Electrical heating
- Electric A/C compressor (EKK)
- Electric motor
High-voltage cables must not be repaired. In the event of damage, the high-voltage cable must be fully replaced!
Bending radius of a high-voltage cable
- High-voltage cable
- Bending radius must be greater than 70 mm
The high-voltage cables must not be excessively bent or kinked The bending radius must not be less than 70 mm Excessive kinking/bending of the high-voltage cable may result in damage to the cable shielding and thus to an isolation fault in the high-voltage vehicle electrical system.
Work on live high-voltage components is expressly prohibited. Prior to every operation which involves a high-voltage component, it is essential to disconnect the high-voltage system from the voltage supply and to secure it against unauthorized return to service.
- Charging plug is not connected to the vehicle.
- Enter the PARK vehicle condition (e.g. by holding down the media button of the head unit).
- Wait until the vehicle enters "sleep mode" (identifiable by the fact that the START-STOP button is not illuminated).
- Open high-voltage safety connector.
- Secure the high-voltage system against restarting at the high-voltage service disconnect.
- Activate PAD mode (e.g. by operating the START-STOP button three times within 0.8 s).
- Wait until the Check Control message "High-voltage system switched-off" is displayed in the instrument cluster.
- Enter PARK vehicle condition.
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Removing the flat high-voltage connector
Bridge for high-voltage interlock loop
Before the high-voltage connector can be
disconnected, the bridge for the high-voltage
interlock loop must first be removed. The bridge
closes the circuit
Removing the round high-voltage connector
The following figures show the approach for releasing the round high-voltage
connector, as used
for example on the high-voltage cable from the Electrical Machine Electronics to
the convenience
charg
Connection for potential compensation lines
The isolation monitoring determines whether the isolation resistance between
active high-voltage
components (e.g. high-voltage cables) and ground is above or below a required
minimum value. If
the i
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High-voltage power management
The power management for the high-voltage vehicle electrical system includes
two subfunctions: one
for driving and one for charging mode.
In driving mode, the energy flows from the high-voltage battery unit to the
high-voltage consumers
and the energy flows during energy recovery to the high-volt
Coordinating the charging procedure
Coordination for starting and ending the charging procedure is performed by
the high-voltage power
management in the EME.
The following actions required by the customer at the start of the charging
procedure:
Adjust the desired charge current level in ampere
Set the start time for charging
Co
