Checklist for scheduled inspection CESG (FUP3 - check)

Checklist for scheduled inspection of the safety system

The implementation of the hydrogen tank system in all BMW Hydrogen 7 vehicles meets very high safety standards. In order to ensure that the overall framework consisting of the Clean Energy Control Unit and the engine application software specially adapted for the hydrogen system at all times works perfectly, regular functional checks of the safety system are absolutely necessary.

The checklist below, alongside the corresponding repair instructions, serves as a guide to the proper procedure and describes the chronological sequence of the check. The checking options in the adjacent test module, the statuses that can be read out and reading the fault code memory in the control unit functions of the Clean Energy Control Unit (CESG) only support this checklist. In order to carry out various activations and checks of states (above all the valves), a so-called ”FUP box” is required.

Before starting each functional check of the safety system, this FUP box is to be connected to the integrated system in accordance with the repair instructions!

Before the start of any work, the Moviline control unit should be disconnected to suppress the transmission of the fault code memory entries that arise during this FUP test to BMW headquarters. After completion of all work, the Moviline control unit must be reconnected!

Notes:

1.) It is recommended to print this checklist and use a pen to manually 'cross off' the individual points to mark the progress and the individual reactions as well as to make notes that document the individual checks ...

2.) Before each individual check as well as after triggering each abort criterion (see below) and also after every application of gas to an H2 sensor (see below), delete the fault code memory. It goes without saying that any faults are to be remedied in line with the accepted principled BEFORE the start OF ANY work.

3.) Every time the power supply of the Clean Energy Control Unit is interrupted (for example, by pulling the wiring harness connector), the entire fault code memory and information memory must be deleted. Thereafter, this control unit must be placed in the sleep mode. ... These measures filter fault code memory entries that are caused by disconnecting the control unit.

4.) Furthermore, after each concluded partial check by triggering an abort criterion by actuating switches on the FUP box, all actuated switches are to be returned to their initial position.

5.) Tests with opened fuel filler flap and current loop adapter:
After every concluded partial test by triggering an interrupt criterion, the current loop adapter must be inspected. The fuel filler flap must be closed, as otherwise no refuelling release can be given.

6.) After every concluded partial test, the engine must be started in the H2 mode so that the pressure accumulator of the pneumatic valves can be applied 14 bar absolute pressure!

Warnings / must be observed!

All scheduled appointments to check the safety system must be kept!

A BMW Hydrogen 7 vehicle may only leave the workshop when all the functional checks have been cleared as ”OK” by qualified service technicians!

No check may be omitted.

The following seven tests are essential components of the functional check of the safety system (FUP 3):

• Check of the gas warning system (GWA) in the mode >Park<
  
• Check of the refuelling abort by gas warning system (GWA)
  
• Check of the engine start interlock during refuelling
  
• Check of the refuelling abort
  
• Check of the GWA in the mode >Drive<
  
• Check of the reaction in the event of malfunctions in the H2 mode
  
• Check of the freezing of the coolant heat exchanger (KWWT)
  
  
  

Test 1: gas warning system in the mode >Park<

• Preparation / required resources:
  Action: Print out the relevant repair instructions (RA 61 35 HX9 Hydrogen sensor in the engine compartment as well as RA 6135 H10 Hydrogen sensor in the headlining).
  Action: make both H2 sensors (inside vehicle and engine compartment) accessible.
  Action: close all the windows. Close all doors and windows and get out of the vehicle.
  (Note: If the radio head is connected by a cable with the tester, this cable is to be routed through a slightly opened window.)
  Action: provide test gas with H2 concentration of 3.0 volume percent (Vol%) as well as sensor adapter.
  
• Precondition of the vehicle in each case:
  Action: remove the ignition key (= terminal 0).
  Repeated action: place the Clean Energy Control Unit in the sleep mode before applying test gas to each H2. This idle state should be set using the test module listed on the right-hand side.
  Repeated action: before applying gas to each H2 sensor, connect the gas application hose to the sensor that is to be checked.
  
• Apply test gas to the H2 sensors:
  Repeated action: in succession, both H2 sensors are to be applied test gas until the H2 alarm is triggered. The high alarm must trigger in each case at 2.0 Vol%. The test gas is to be introduced at the following positions:
  Note: the time up to the alarm triggering can be up to 10 minutes.
  
  1. see RA 61 35 H10 (interior sensor)
     
  2. see RA 61 35 HX9 (engine compartment sensor)
     
• Check of the reactions:
  Action: once each alarm has been issued, switch on terminal R and continue the diagnosis session (connect diagnostic head).
  Use the test module: check whether 3.) resulted in fault code memory entries / information memory entries for each H2 sensor.
  Visual inspection: check whether the side windows open in the event of H2 alarm in the interior. The side windows may only not open when the gas is applied to the H2 sensor in the engine compartment.
  Visual inspection: check the display in the instrument cluster. The display may only appear after the ignition key has been inserted (= terminal R). The display is only shown until an H2 alarm is signalled.
  Visual inspection: check whether with each of the repeated checks using sensor gas application the four warning LEDs in the doors flash (the LEDs must flash).
  
• Conspicuous aspects and comments:
  Action: make hand-written notes regarding other conspicuous aspects and note down comments.
  
  
  
  
  
  

Test 2: refuelling abort by gas warning system

• Preparation / required resources:
  Action: print out the relevant repair instructions (RA 16 00 H22 Connecting the current loop adapter / RA 6135 H12 Hydrogen sensor NSK / RA 61 35 H13 Hydrogen sensor filler pipe / RA 16 00 H24 Connecting the FUP box)
  Action: attach the current loop adapter to the tank filling side.
  Action: make both H2 sensors accessible (at fill coupling and secondary system capsule).
  Action: provide test gas with H2 concentration of 3.0 volume percent (Vol%) as well as sensor adapter.
  
• Precondition of the vehicle:
  Action: generate refuelling release on the vehicle. Proceed as follows:
  
  1. Place the vehicle in the position terminal R active.
     
  2. Create internal tank pressure in the hydrogen tank of less than 5.3 overpressure bar.
     Note: this is possible when the vehicle is operated in the hydrogen mode when stationary. The overpressure can be read out via a corresponding menu in the instrument cluster or also in the control unit functions.
     
  3. Ensure a tank fill level (hydrogen tank content) of less than 80 % (corresponds to less than 7200 grams).
     
  4. Switch off the engine and place the gear selector lever in position P an engage the parking brake (EMF).
     
  5. Place the vehicle in a state in which there is no gas warning - and is not stored in the fault code memory either.
     
  6. Ensure that the engine shutdown valve(s) is(are) closed (this can be determined by running a query in the control unit functions for the CE control unit).
     Note: In general, the following applies to the CE control unit: closed valves always return a PWM value of 0 %.
     
  7. Ensure that no crash signal or no stored fault for a detected crash is stored in the fault code memory (this can be determined by running a query in the control unit functions for the CE control unit) and make sure that the crash sensor system (ISIS) is active.
     
  8. Ensure that no fault is stored for components of the gas warning system in the fault code memory.
     Note: Faults that might be stored are to be remedied in line with accepted technical principled prior to any other work. If applicable, minor sensor faults can be ignored and/or deleted.
     
  9. Ensure that the vehicle electrical system battery as well as the CE batteries are adequately charged (i.e. more than 70 %).
     Note: low charge states generate fault code memory entries.
     
  Action: request refuelling release by pressing the fuel filler flap switch twice (the fuel filler flap must open).
  Action: connect the current loop adapter (the vehicle is now ready for refuelling).
  Note: The ”SS” LED lights up on the FUP box to confirm a closed current loop.
  Check the FUP box: The filling valves for gaseous (BEV_G) and liquefied (BEV_F) always light up when these valves are opened (for refuelling the hydrogen tank, these valves must be open - the corresponding LEDs ”BEV_F” and ”BEV_G” must light up).
  
  
• Apply test gas to the H2 sensors:
  Repeated action: in succession, both H2 sensors are to be applied test gas until the H2 alarm is triggered. The alarm must trigger in each case at 2.0 Vol%. The test gas is to be introduced at the following positions:
  
  1. see RA 61 35 H12 (NSK sensor)
     
  2. see RA 61 35 H13 (fill coupling sensor)
     
• Check of the reactions:
  Use the control unit functions: check whether 3.) has led to fault code memory entries for each H2 sensor as a result of each gas application (the test must lead to faults being stored).
  Visual inspection: check the display in the instrument cluster. The display may only appear after the ignition key has been inserted (= terminal R). The display is only shown until an H2 alarm is signalled.
  Visual inspection: check whether with each of the repeated checks using sensor gas application the four warning LEDs in the doors flash (the LEDs must flash).
  Check the FUP box: check whether the refuelling is now prevented. For prevented refuelling, the current loop must be interrupted (the previously lit up LED ”SS” must go out). Prevented refuelling can be recognised in that the LEDs ”BEV_F” and ”BEV_G” have gone out.
  
• Conspicuous aspects and comments:
  Action: make hand-written notes regarding other conspicuous aspects and note down comments.
  
  
  
  
  
  

Test 3: interlock of the engine start during refuelling

• Preparation / required resources:
  Action: print out the relevant repair instructions (RA 16 00 H22 Connecting the current loop adapter / RA 16 00 H24 Connecting the FUP box)
  Action: attach the current loop adapter to the tank filling side.
  
• Precondition of the vehicle:
  Action: generate refuelling release on the vehicle. Proceed as follows:
  
  1. Place the vehicle in the position terminal R active.
     
  2. Create internal tank pressure in the hydrogen tank of less than 5.3 overpressure bar.
     Note: this is possible when the vehicle is operated in the hydrogen mode when stationary. The overpressure can be read out via a corresponding menu in the instrument cluster or also in the control unit functions.
     
  3. Ensure a tank fill level (hydrogen tank content) of less than 80 % (corresponds to less than 7200 grams).
     
  4. Switch off the engine and place the gear selector lever in position P an engage the parking brake (EMF).
     
  5. Place the vehicle in a state in which there is no gas warning - and is not stored in the fault code memory either.
     
  6. Ensure that the engine shutdown valve(s) is(are) closed (this can be determined by running a query in the control unit functions for the CE control unit).
     Note: In general, the following applies to the CE control unit: closed valves always return a PWM value of 0 %.
     
  7. Ensure that no crash signal or no stored fault for a detected crash is stored in the fault code memory (this can be determined by running a query in the control unit functions for the CE control unit) and make sure that the crash sensor system (ISIS) is active.
     
  8. Ensure that no fault is stored for components of the gas warning system in the fault code memory.
     Note: Faults that might be stored are to be remedied in line with accepted technical principled prior to any other work. If applicable, minor sensor faults can be ignored and/or deleted.
     
  9. Ensure that the vehicle electrical system battery as well as the CE batteries are adequately charged (i.e. more than 70 %).
     Note: low charge states generate fault code memory entries.
     
  Action: request refuelling release by pressing the fuel filler flap switch twice (the fuel filler flap must open).
  Action: connect the current loop adapter (the vehicle is now ready for refuelling).
  Note: The ”SS” LED lights up on the FUP box to confirm a closed current loop.
  Check the FUP box: The filling valves for gaseous (BEV_G) and liquefied (BEV_F) always light up when these valves are opened (for refuelling the hydrogen tank, these valves must be open - the corresponding LEDs ”BEV_F” and ”BEV_G” must light up).
  
  
• Triggering the abort criterion or engine start:
  Action: (attempt to) start the engine.
  
• Check of the reactions:
  Check: check whether the attempted engine start led to refuelling being aborted (the refuelling must have been aborted). Furthermore, check whether the engine start was prevented by an active starter motor lock relay (the engine start must have been prevented by an active starter motor lock relay). The >Status starter motor lock< can be queried in the control unit functions for the CE control unit.
  
• Conspicuous aspects and comments:
  Action: make hand-written notes regarding other conspicuous aspects and note down comments.
  
  
  
  
  
  

Test 4: refuelling abort criteria

• Preparation / required resources:
  Action: print out the relevant repair instructions (RA 16 00 H22 Connecting the current loop adapter / RA 16 00 H24 Connecting the FUP box)
  Action: attach the current loop adapter to the tank filling side.
  
• Precondition of the vehicle:
  Action: generate refuelling release on the vehicle. Proceed as follows:
  
  1. Place the vehicle in the position terminal R active.
     
  2. Create internal tank pressure in the hydrogen tank of less than 5.3 overpressure bar.
     Note: this is possible when the vehicle is operated in the hydrogen mode when stationary. The overpressure can be read out via a corresponding menu in the instrument cluster or also in the control unit functions.
     
  3. Ensure a tank fill level (hydrogen tank content) of less than 80 % (corresponds to less than 7200 grams).
     
  4. Switch off the engine and place the gear selector lever in position P an engage the parking brake (EMF).
     
  5. Place the vehicle in a state in which there is no gas warning - and is not stored in the fault code memory either.
     
  6. Ensure that the engine shutdown valve(s) is(are) closed (this can be determined by running a query in the control unit functions for the CE control unit).
     Note: In general, the following applies to the CE control unit: closed valves always return a PWM value of 0 %.
     
  7. Ensure that no crash signal or no stored fault for a detected crash is stored in the fault code memory (this can be determined by running a query in the control unit functions for the CE control unit) and make sure that the crash sensor system (ISIS) is active.
     
  8. Ensure that no fault is stored for components of the gas warning system in the fault code memory.
     Note: Faults that might exist are to be remedied in line with accepted technical principled prior to any other work. If applicable, minor sensor faults can be ignored and/or deleted.
     
  9. Ensure that the vehicle electrical system battery as well as the CE batteries are adequately charged (i.e. more than 70 %).
     Note: low charge states generate fault code memory entries.
     
  Action: request refuelling release by pressing the fuel filler flap switch twice (the fuel filler flap must open).
  Action: connect the current loop adapter (the vehicle is now ready for refuelling).
  Note: The ”SS” LED lights up on the FUP box to confirm a closed current loop.
  Check the FUP box: The filling valves for gaseous (BEV_G) and liquefied (BEV_F) always light up when these valves are opened (for refuelling the hydrogen tank, these valves must be open - the corresponding LEDs ”BEV_F” and ”BEV_G” must light up).
  
  
• Triggering the eight abort criteria:
  repeated deployment of the FUP box: In the following section, 8 abort criteria are checked. After each individual triggering of an abort criterion, the reaction in each case must be checked immediately (see 4.). The reactions stated at 4.) apply to each abort criterion (comments are supplied for exceptions to this rule). The individual abort criteria are as follows:
  
  1. Set the internal tank pressure higher than 5.95 bar overpressure - actuating the tank pressure switch P_Tank 1 or P_Tank 2 at the FUP box increases the internal tank pressure.
     Note: None of the four LEDs on the FUP box may still be lit after actuation.
     
  2. Set the internal tank pressure higher than 5.95 bar overpressure - by simultaneously actuating the tank pressure switches P_Tank 1 as well as P_Tank 2 at the FUP box.
     Note: None of the four LEDs on the FUP box may still be lit after actuation.
     
  3. Switch on ignition (i.e. terminal 15 on) and then release the parking brake (EMF).
     
  4. Do not place the selector lever in position P or from position P to position N.
     Note: None of the four LEDs on the FUP box may still be lit 20 seconds after the abort criterion has triggered.
     
  5. Allow the overfill protection system to trigger - by actuating the switch L_Stop1 or L_Stop2 on the FUP box.
     Note: None of the four LEDs on the FUP box may still be lit 20 seconds after the abort criterion has triggered.
     Allow the overfill protection system to trigger - by simultaneously actuating the switches L_Stop1 and L_Stop2 on the FUP box.
     Note: None of the four LEDs on the FUP box may still be lit 20 seconds after the abort criterion has triggered.
     
  6. Set the tank pressure as lower than 0.9 bar by allowing air to enter the fuel tank. You do so by simultaneously actuating the tank pressure switch P_Tank 1 as well as P_Tank 2 on the FUP box.
     Note: None of the four LEDs on the FUP box may still be lit after actuation.
     
  7. Simulate a detected crash - by setting the SBK switch on the FUP box to switch position 1 (the >Input value crash sensor< can be queried in the control unit functions for the CE control unit).
     
  8. Abort due to removal of the filling station release signal by opening the current loop. Note: None of the four LEDs on the FUP box may still be lit 20 seconds after the abort criterion has triggered.
     
• Check the reactions - necessary after each individual triggering of an abort criterion:
  Action: After each check of an abort criterion, it must be checked whether the relevant fault code memory entry has been stored (automatic entries must be made in the fault code memory in each case).
  Before checking the next abort criterion, each of the stored faults must be deleted.
  Visual inspection: check of the display in the instrument cluster - a prevented engine start in the hydrogen mode should be recognisable by a corresponding display in the instrument cluster, e.g.: ”H2 system disrupted”.
  Visual inspection of the FUP box: check whether the refuelling and also the possibility of an engine start in the hydrogen mode have now been prevented. For prevented refuelling, the current loop must be interrupted (this must be confirmed by the LED ”SS” going out).
  Note: the prevention of refuelling mentioned above may only occur after triggering the abort criteria b), f) as well as g)!
  
• Conspicuous aspects and comments:
  Action: make hand-written notes regarding other conspicuous aspects and note down comments.
  
  
  
  
  
  

Test 5: gas warning system in the mode >Driving<

• Preparation / required resources:
  Action: print out the relevant repair instructions (RA 61 35 H10 Hydrogen sensor in the headlining / RA 61 35 H11 Hydrogen sensor in the luggage compartment / RA 16 00 H24 Connecting the FUP box).
  Action: make both H2 sensors accessible (inside of vehicle and luggage compartment).
  Ensure: there must be sufficient hydrogen in the fuel tank to enable a start in the hydrogen mode.
  Action: provide test gas with H2 concentration of 3.0 volume percent (Vol%) as well as sensor adapter.
  
• Precondition of the vehicle in each case:
  Action: start the vehicle in the hydrogen mode.
  Note: Generally applicable: The confirmation that the BMW Hydrogen 7 vehicle is in the hydrogen mode is provided by the LEDs ”MAV” as well as ”BEV_G” on the FUP box coming on.
  Action: close all the windows.
  
• Apply test gas to the H2 sensors:
  Repeated action: in succession, both H2 sensors are to be applied test gas until the H2 alarm is triggered. The high alarm must trigger in each case at 2.0 Vol%. The test gas is to be introduced at the following positions:
  
  1. see RA 61 35 H10 (inside of vehicle)
     
  2. see RA 61 35 H11 (luggage compartment)
     
  Repeated deployment of the FUP box: after every triggered alarm, a changeover to the petrol mode must be made. The detection of the petrol mode is provided by the FUP box in that the LEDs ”MAV” and ”BEV_G” go out.
  
• Check of the reactions:
  Visual inspection: check after every manual changeover to the petrol mode controlled by the FUP box that this has taken place as desired. This should be recognisable by a corresponding display in the instrument cluster, e.g.: ”H2 system disrupted”.
  Use the control unit function: check whether 3.) resulted in fault code memory entries for each H2 sensor.
  Visual inspection: check whether the side windows open in the event of H2 alarm in the interior. The side windows may only open when the gas is applied to the H2 sensor inside the vehicle /passenger compartment).
  Visual inspection: check the display in the instrument cluster. The display may only appear after the ignition key has been inserted (= terminal R). The display is only shown until an H2 alarm is signalled.
  Visual inspection: check whether with each gas application the four warning LEDs in the doors flash (the LEDs must flash).
  
• Conspicuous aspects and comments:
  Action: make hand-written notes regarding other conspicuous aspects and note down comments.
  
  
  
  
  
  

Test 6: reaction in the event of malfunctions in the H2 mode

• Preparation / required resources:
  Action: print out the relevant repair instructions (RA 16 00 H24 Connecting the FUP box).
  Ensure: there must be sufficient hydrogen in the fuel tank to enable a start in the hydrogen mode.
  
• Precondition of the vehicle in each case:
  Action: start the vehicle in the hydrogen mode.
  Note: The confirmation that the vehicle is in the hydrogen mode is provided by the LEDs ”MAV” as well as ”BEV_G” on the FUP box coming on.
  
• Triggering an abort criterion:
  Action: introduce air into the tank - by simultaneously actuating the tank pressure switch P_Tank 1 as well as P_Tank 2. Both switches must be set to switch position < 0.9 bar overpressure.
  Check the FUP box: after triggering the abort criterion, the two LEDs ”MAV” as well as ”BEV_G” must go out.
  Action: introduce air into the tank by simultaneously actuating the tank pressure switch P_Tank 1 as well as P_Tank 2. Both switches must be set to switch position > 5.95 bar overpressure.
  Check the FUP box: after triggering the abort criterion, the two LEDs ”MAV” as well as ”BEV_G” must go out.
  
• Check of the reactions:
  Visual inspection: check after the manual changeover to the petrol mode controlled by the FUP box that this has taken place as desired. This should be recognisable by a corresponding display in the instrument cluster.
  Use the control unit function: check whether 3.) led to the fault code memory entry ”Refuelling prevented” being written in the fault code memory (the fault code memory entry ”Refuelling prevented” must be written in the fault code memory).
  
• Conspicuous aspects and comments:
  Action: make hand-written notes regarding other conspicuous aspects and note down comments.
  
  
  
  
  
  

Test 7: freezing of the coolant heat exchanger

• Preparation / required resources:
  Action: print out the relevant repair instructions (RA 16 00 H24 Connecting the FUP box).
  Ensure: there must be sufficient hydrogen in the fuel tank to enable a start in the hydrogen mode.
  
• Precondition of the vehicle in each case:
  Action: start the vehicle in the hydrogen mode (check the corresponding display on the FUP box).
  
• Triggering the four abort criteria:
  Repeated deployment of the FUP box: In the following section, 4 abort criteria are checked. After each individual triggering of an abort criterion, the reaction in each case must be checked immediately (see 4.). The individual abort criteria are as follows:
  
  1. Set the temperature of the tank to less than -30 degrees Celsius - by actuating the selector switch T_WT on the FUP box.
     
  2. Set the temperature of the engine shutdown valve to less than -30 degrees Celsius - by actuating the selector switch T_MAV on the FUP box.
     
  3. Set the temperature of the coolant feed to less than -30 degrees Celsius - by actuating the selector switch T_KWVL on the FUP box.
     
  4. Set the temperature of the engine coolant return to less than -30 degrees Celsius - by actuating the selector switch T_KWRL on the FUP box.
     
  Visual inspection of the FUP box: triggering each abort criterion must lead to an automatic changeover from the hydrogen mode to the petrol mode. This is confirmed on the FUP box in that the LEDs ”MAV” as well as ”BEV_G” go out.
  
• Check of the reactions:
  Visual inspection: check after every manual changeover to the petrol mode controlled by the FUP box that this has taken place as desired. This should be recognisable by a corresponding display in the instrument cluster, e.g.: ”H2 system disrupted”.
  Use the control unit function: checking whether 3.) led to fault code memory entries being written in the fault code memory (fault code memory entries must have been written).
  
• Conspicuous aspects and comments:
  Action: make hand-written notes regarding other conspicuous aspects and note down comments.