e-GoKart Powertrain Young Star Manual · # The CUSTOMER is responsible for the review and...

e-GoKart Powertrain "Young Star"

Manual

2 20/01/2020

Content

ii / 60 e-GoKart_Powertrain__Young_Star__Manual Bosch Motorsport

Content1 Getting Started................................................................................................................................................................ 3

2 Introduction .................................................................................................................................................................... 42.1 Conditions of Use................................................................................................................................................................................................. 4

3 System.............................................................................................................................................................................. 83.1 System Description .............................................................................................................................................................................................. 83.2 System Architecture............................................................................................................................................................................................. 93.3 System Functions.................................................................................................................................................................................................. 103.4 System Integration............................................................................................................................................................................................... 133.5 System Performance ........................................................................................................................................................................................... 133.6 System Operation................................................................................................................................................................................................. 14

4 Component Description ................................................................................................................................................. 164.1 Vehicle Control Unit VCU MS 40 .................................................................................................................................................................... 164.2 Energy Storages ES 5-2.4................................................................................................................................................................................... 174.3 Power Unit PU 5-10 ............................................................................................................................................................................................. 194.4 DC/DC Converter.................................................................................................................................................................................................. 224.5 Charger Energy Storage CH 5-1.2.................................................................................................................................................................. 234.6 Display Unit DDU 18............................................................................................................................................................................................ 29

5 Overall Integration Requirements of e-GoKart System Components into the Superior Vehicle Context............ 315.1 Electrical Integration............................................................................................................................................................................................ 315.2 Mechanical Integration ...................................................................................................................................................................................... 315.3 Component Integration Requirements........................................................................................................................................................ 32

6 Wiring Harness instruction / Build up chassis............................................................................................................. 416.1 Implement the Components............................................................................................................................................................................ 416.2 Vehicle Control Unit VCU MS 40 .................................................................................................................................................................... 58

7 Troubleshooting.............................................................................................................................................................. 59

Getting Started | 1

Bosch Motorsport e-GoKart_Powertrain__Young_Star__Manual 3 / 60

1 Getting Started

DisclaimerDue to continuous enhancements we reserve the rights to change illustrations, photos ortechnical data within this manual. Please retain this manual for your records.

Before startingBefore starting your engine for the first time, install the complete software. BoschMotorsport software is developed for Windows operation systems. Read the manual care-fully and follow the application hints step by step. Don’t hesitate to contact us. Contactdata can be found on the backside of this document.

CAUTION

Risk of injury if using the Powertrain e-GoKart inappropriately.Use the Powertrain e-GoKart only as intended in this manual. Any maintenance or repairmust be performed by authorized and qualified personnel approved by Bosch Motorsport.

CAUTION

Risk of injury if using the Powertrain e-GoKart with uncertified com-binations and accessoriesOperation of the Powertrain e-GoKart is only certified with the combinations and ac-cessories that are specified in this manual. The use of variant combinations, accessoriesand other devices outside the scope of this manual is only permitted when they havebeen determined to be compliant from a performance and safety standpoint by a repres-entative from Bosch Motorsport.

NOTICE

For professionals onlyThe Bosch Motorsport Powertrain e-GoKart was developed for use by professionals andrequires in depth knowledge of automobile technology and experience in motorsport. Us-ing the system does not come without its risks.

It is the duty of the customer to use the system for motor racing purposes only and noton public roads. We accept no responsibility for the reliability of the system on publicroads. In the event that the system is used on public roads, we shall not be held respons-ible or liable for damages.

2 | Introduction

4 / 60 e-GoKart_Powertrain__Young_Star__Manual Bosch Motorsport

2 IntroductionThis system specification is a technical documentation of the BOSCH MOTORSPORT 48 VE-GoKart System. It describes the E-GoKart System architecture, system components, per-formance and functions, as well as the integration and application of the system in E-GoKarts.

Furthermore this document informs the CUSTOMER about the product concerning

– intended use,

– forbidden misuse,

– operation conditions,

– validation,

– requirements to the superior vehicle system,

– requirements to the CUSTOMER for correct and safe use,

– requirements for integration and application of the product in the superior vehiclesystem,

– responsibilities.

List of terms used in this documentTerm Explanation

CUSTOMER The CUSTOMER is the purchaser of the sys-tem, described in this document. If theCUSTOMER is not the vehicle manufacturer,this party has to ensure, that the obliga-tions of the vehicle manufacturer are real-ized by the vehicle manufacturer. This aimsespecially to the compliance with the bot-tom up requirements.

BOSCH MOTORSPORT BOSCH Engineering GmbH as the manufac-turer / supplier of BOSCH MOTORSPORT E-GoKart System, described in this document.

2.1 Conditions of Use

2.1.1 Terms and Specifications for Product LiabilityPlease be especially aware of all conditions states in the following section.

Business relations concerning use of sample parts:

Conditions which have been agreed on for series parts do not apply for sample parts.

Warranty:

BOSCH MOTORSPORT will only warrant CUSTOMER samples to be free of productionfaults. All other warranties expressed or implied are excluded unless otherwise required bylaw. BOSCH MOTORSPORT warrants products to comply with deliverable requirementsand does not warrant the CUSTOMER calibration. Any claim for damages, in particular,concerning consequential loss, is excluded as far as there is no legal liability. Warranty ofdeliverables is limited to either full replacement of the part or repair. Warranties exceed-ing contents of this document in terms of function, reliability or safety do not apply.

Introduction | 2


2.1.2 Safety and Warning NotesTo avoid the risk of an electric shock, which can lead to death or serious injury, any shortcircuit of the interfaces (poles) of the Energy Storages ES 5-2.4, e.g. by tool drop, shall beavoided.

2.1.3 Conditions for Transport and StorageStorage of the product between shipment from BOSCH MOTORSPORT plant and mount-ing/initial operation at the CUSTOMER shall be realized in defined transport packaging.

# Deliverables shall be handled with care.

If possible, all BOSCH MOTORSPORT e-GoKart System components are shipped as com-plete units packed securely in appropriate transportation devices to protect the compon-ents from damage or corrosion (protection against dust, moisture, precipitation, solar irra-diation, etc.) that may result from usual transportation conditions.

# The CUSTOMER shall inform BOSCH MOTORSPORT if irregular / special transportationconditions may occur having an impact on usual transportation devices applied.

# During storage of unpacked components at CUSTOMER site the CUSTOMER shall en-sure that products are protected against damage or corrosion.

# Deliverables shall be stored for maximum 1 year.

# Deliverables shall only be transported or stored with an environment temperature<80°C.

If above conditions are not fulfilled, the intended application is only allowed after inspec-tion and agreement by BOSCH MOTORSPORT. Related expenses have to be compensatedby the CUSTOMER.

# Deliverables shall not be stored in humid/moist conditions (especially in case of overseatransportation) and shall never be exposed to extreme heat or fire nor corrosive sub-stances. This applies to installed and uninstalled units as well as packed and unpackedunits. If components are strongly subjected to water (e.g. due to transportation, applica-tion of a cleaning process), a drying process shall be performed before storing those.

# Deliverables are not allowed to fall or be subjected to uncommon stresses (temperature,acceleration, ultraviolet rays, etc.). In these circumstances further use of the deliverables isnot permitted.

# During storage, all external electrical connections from the application input/output in-terfaces and the power connector shall be removed and connector inserts, where sup-plied, fitted.

# During storage or transport of the unpacked BOSCH MOTORSPORT e-GoKart Systemelectrostatic charging and discharging of unpacked Energy Storages ES 5-2.4 shall beavoided.

# There shall never be placed any heavy objects on unpacked deliverables (especially the48 V Energy Storages ES 5-2.4) or the inter-connecting cables.

# The Power Unit 5-10 shall be transported or stored horizontally.

# Axial loads or shocks on the rotor shaft of the unpacked e-GoKart Drive unit are notpermitted. This may result in pre-damage of bearings. This applies also to operation.

# The Power Unit 5-10 is not allowed to fall or be subjected to uncommon stresses (tem-perature, acceleration, ultraviolet rays, etc.). Under these circumstances, further use of thee-GoKart Drive unit is not permitted.

2 | Introduction


# The product's operating safety is only ensured if the permissible conditions are met.

If a 48 V Energy Storage ES 5-2.4 is stored or not operated it can be stored for 6 monthswith start-SOC of ≥30 % for each 48 V Energy Storage ES 5-2.4 without recharging. TheEnergy Storages ES 5-2.4 are delivered with an initial SOC ≥25 %. A check of the SOC ofthe delivered energy storages is recommended before storage. This applies also for 48 VEnergy Storages 5-2.4 installed in the vehicle.

# The CUSTOMER is responsible for the review and application of all applicable regula-tions as well as industry standards for lifting deliverables.

# Do not modify or alter any component. In case, it is necessary to modify or alter com-ponents (e.g. the Energy Storage 5-2.4), contact BOSCH MOTORSPORT in advance.

Energy Storages 5-2.4 have a low internal impedance and may provide damaging currentsif misconnected.

# Reverse polarity and operation with disconnected plug shall be avoided.

# The outer temperature of deliverables increases during operation causing temperatureradiation. If necessary, the CUSTOMER shall install protection for limiting the temperatureradiation. If necessary, the CUSTOMER shall install thermal insulation measures in order toavoid damage of adjacent components.

2.1.4 Environmental ConditionsThe BOSCH MOTORSPORT e-GoKart System is designed for an operation in typicalEuropean climate zones with an ambient temperature of 5 to 35°C. Operation with re-duced performance is possible for -8 to 40°C ambient temperature. Performance reduc-tion depends on the application and vehicle design. Charging and recuperation is possiblefor >5°C ambient temperature.

Inner temperatures of components might differ from ambient temperature due to installa-tion position and operation history. The BOSCH MOTORSPORT e-GoKart System measuresthe temperature of the 48 V Energy Storage ES 5-2.4 on cell level. If the cell temperatureexceeds defined limits (-8 to 58°C for driving and 5 to 44°C for charging), the BOSCH MO-TORSPORT e-GoKart System autonomously prevents driving and charging and informsthe driver, see section System Screens [} 14].

Illustration 1: Temperature Range

The BOSCH MOTORSPORT e-GoKart System is designed for an environment with a relat-ive humidity of 0 to 80 %.

2.1.5 Maintenance and Repair# The CUSTOMER shall ensure that electrical connection and electrical isolation of thecomponents are reliable over lifetime. It is recommended that during frequent service ofthe vehicle the following checks are executed to ensure safe operation:

Introduction | 2


– Adequate and reliable electrical connection between charger housing and vehiclechassis has to be ensured. No corrosion of the interface from charger housing tochassis and multiple chassis parts, if applicable. This is to ensure the protective earthconnection from AC-plug to vehicle.

– Tightening torque of the termination bolts of the Power Unit PU 5-10, Energy StorageES 5-2.4, Charger Energy Storage CH 5-1.2 and 48 V star point interconnection - if ap-plicable - have to be checked.

– AC cable from AC plug to Charger Energy Storage CH 5-1.2 has to be checked. If thecable has any damages, it has to be replaced. It is not allowed to use a vehicle withdefect AC cable.

– All movable cables have to be checked, e.g. cables to the Power Unit PU 5-10, if thePower Unit PU 5-10 is integrated in rear swinging fork.

– If the isolation is defect, the cable has to be exchanged or repaired.

# Service and repair or replacement of the product may only be performed by authorizedstaff.

There are no user serviceable parts in the Energy Storage ES 5-2.4. Delivered lithium-ionEnergy Storages ES 5-2.4 are designed to be maintenance free, when during use recom-mended operating and charging instructions are met.

3 | System


3 SystemThe e-GoKart System combines traditional karting and future-oriented technology. Highenergy and power density of the air-cooled system components are ideal for small andlightweight vehicles like e-GoKarts. With high torque, the e-GoKart System supports con-vincing driving behavior and fun-to-drive. The e-GoKart System provides high power overa wide range for maximum vehicle speed. By intelligent software, the e-GoKart Systemgets the best out of the vehicle at any time and any driving profile, energy recuperationincluded. The system is safe and reliable based on automotive qualified components anda development approach according to automotive standards. The e-GoKart System is aplatform for easy scalability over different vehicle classes and types.

3.1 System DescriptionThe BOSCH MOTORSPORT e-GoKart System perfectly harmonizes components for aneasy and fast electrification and a unique driving experience. Therefore several compon-ents are connected in a system context to form a high performance system to meet theneeds of the CUSTOMER.

The following figure shows schematically the BOSCH MOTORSPORT e-GoKart Systemcomponents in a typical electric rental kart application: Power Unit PU 5-10, Energy Stor-age ES 5-2.4 (48 V lithium-ion battery pack(s)), Vehicle Control Unit VCU MS 40, ChargerEnergy Storage CH 5-1.2, DC/DC converter and Display Unit DDU 18. All these compon-ents are combined and connected to the BOSCH MOTORSPORT e-GoKart System toprovide optimal performance for the CUSTOMER vehicle.

Illustration 2: Overview of the BOSCH MOTORSPORT e-GoKart System components

System | 3


3.2 System Architecture

3.2.1 Voltage Level 12 V and 48 V NetThe traction net has a nominal voltage of 48 V.

There is an additional voltage net for power supply of the low-voltage components (e.g.Vehicle Control Unit VCU MS 40, Display Unit DDU 18, auxiliary components) with avoltage of 12 V.

12 V voltage rangeVoltage Effect

-12 V Reverse polarity; damage of the system pos-sible.

<6 V System cannot be activated.

During driving cycle, system will shut-off.

Driver has to turn the key (terminal 15) torestart the system.

6 to 8 V System will remain active, but will not sup-port driving torque.

System returns automatically to full func-tionality when voltage is >8 V.

8 to 16 V Normal operating range.

>16 V Damage possible

48 V traction net voltage rangeVoltage Effect

32.5 V System will shut-off for the current drivingcycle.

Driver has to turn the key (terminal 15) torestart the system.

System should be charged.

32.5 to 42.25 V System will remain active, but will deratedriving torque.

42.25 to 52 V System returns automatically to full func-tionality when voltage is >36 V.

52 to 54 V Normal operating range.

3.2.2 12 V BatteryThe BOSCH MOTORSPORT e-GoKart System requires a 12 V battery for start-up. Duringoperation the 12 V battery is recharged by the BOSH MOTORSPORT e-GoKart System.

# If the BOSCH MOTORSPORT e-GoKart System is active the 12 V current consumption isabout 0.03 A (Power Unit PU 5-10 ≤ 5.0 mA, DC/DC converter ≤ 20 mA, Charger EnergyStorage CH 5-1.2 ≤ 5.0 mA). This shall be considered for the selection of a suitable 12 Vbattery. It is recommended that the 12 V battery shall have a capacity of at least 6 Ah upto 40 Ah nominal, depending on 12 V consumers / loads in the vehicle. A smaller capacity

3 | System


may be installed but requires calibration of a recharge timer to prevent deep discharge ofthe 12 V battery during long-term storage. The 12 V battery is not in BOSCH MOTORS-PORT scope of delivery.

NOTICE! It is not allowed to implement a different battery type as a lead battery.

3.3 System Functions

3.3.1 Start UpStart-up time for the complete BOSCH MOTORSPORT e-GoKart System is below 2seconds. Within that time the vehicle is ready to drive.

3.3.2 DrivingThe BOSCH MOTORSPORT e-GoKart System provides three different drive mode withpositive (forward) torque. Available drive modes are GO, CRUISE, BOOST. These drivemodes differ in driving performance.

– GO mode implements a performance limitation in order to reach maximum range dueto energy saving.

– CRUISE mode implements driving characteristics balancing performance and energysaving.

– BOOST mode implements driving characteristics for maximum performance of theBOSCH MOTORSPORT e-GoKart System.

When switching the drive modes during driving, torque will be ramped up or down re-spectively, so that no sudden torque variations may occur.

3.3.3 Speed LimiterIn order to make the driving experience for the driver as comfortable as possible theBOSCH MOTORSPORT e-GoKart System implements a speed-limiting function that en-ables a smooth transition towards top speed.

3.3.4 Offboard ChargingCharging the Energy Storage ES 5-2.4 with the Charger Energy Storage CH 5-1.2, as de-scribed in Charger Energy Storage CH 5-1.2 [} 23] is only possible with BOSCH MOTORS-PORT Energy Storages ES 5-2.4.

3.3.5 Range PredictionThe BOSCH MOTORSPORT e-GoKart System calculates the remaining range possible todrive taking into account the current driving conditions and previously measured energyconsumption (history). The predicted range depends on the energy consumption in selec-ted drive mode and thus strongly on the driving behavior of the driver. As the predictedrange is an estimated value, there is no guarantee this range can be reached under all cir-cumstances. The predicted range adapts to the currently selected drive mode. The historycan be reset by the user in the Display DDU 18 configuration menu.

System | 3


If the predicted range is lower than 5 km, the predicted range is not updated anymore un-til the state of charge of the Energy Storages ES 5-2.4 reaches the lower limit. In this casethe predicted range is displayed with a blinking symbol marked with "<5",

3.3.6 Demand and Brake Signal PlausibilizationIn case of implausible demand signals the BOSCH MOTORSPORT e-GoKart System willprevent torque but remain active.

Brake signals are needed for system start. In case of loss of brake signals, driving is locked.

3.3.7 DeratingIf the BOSCH MOTORSPORT e-GoKart System is not able to provide full output power, themaximum power is automatically limited to an allowed level. This temporary limitation iscalled derating and is generally caused by high temperature of the electric machine or anyof the available Energy Storages ES 5-2.4. Derating ensures component protection withouthaving a sudden loss of operation. The power limitation is dynamically based on systemconditions and is reversible, i.e. the system returns to full power as soon as limitation isnot necessary anymore. Active derating is indicated to the driver via a segmented powerbar in the right hand side of the Display DDU 18. If derating is active, segments are fadedout corresponding to the current power limitation.

Illustration 3: Indication of derating: Limited drive power

Derating can also affect recuperation power and thus electrical braking performance.

Illustration 4: Indication of derating: Limited recuperation

3 | System


3.3.8 Malfunction IndicationThe Display DDU 18 is capable to indicate critical faults of the BOSCH MOTORSPORT e-GoKart System to the driver via a dedicated malfunction indication lamp (MIL) implemen-ted as telltale in the Display DDU 18, see blue marked lamp in the following figure.

Illustration 5: Malfunction Indication Lamp

Additionally some internal faults of the BOSCH MOTORSPORT e-GoKart System, e.g. faultsin the torque path, will lead to very limited operation with a minimum allowable speed of5 km/h and low torque. This state is called limp-home operation and enables the driver tobring the vehicle into a safe parking position.

3.3.9 Software Updates (Flashing)Updating the BOSCH MOTORSPORT e-GoKart System software (flashing) is possible for allsystem components via one single system interface with a defined tester-interface infra-structure.

Software updates will be provided by BOSCH MOTORSPORT if necessary.

# It is not allowed to update the software of the BOSCH MOTORSPORT e-GoKart Systemby the CUSTOMER or any other third party without explicit authorization by BOSCH MO-TORSPORT.

3.3.10 Deep Discharge ProtectionOperation of the BOSCH MOTORSPORT e-GoKart System is only possible if the EnergyStorages ES 5-2.4 are charged frequently. Under normal conditions a software functional-ity of the BOSCH MOTORSPORT e-GoKart System operates all Energy Storages ES 5-2.4 invalid operational limits so that no Energy Storage ES 5-2.4 will run in deep discharge state.Once this limit is violated and an Energy Storage ES 5-2.4 is deep discharged, operation ofthe Energy Storage ES 5-2.4 will be prevented by the BOSCH MOTORSPORT e-GoKart Sys-tem.

3.3.11 Shut DownRegular shut down of the system is initiated by terminal 15 switch-off or critical low 12 Vbattery voltage.

System | 3


Illustration 6: ON/OFF switch

3.4 System Integration

3.4.1 Electrical Integration

For the electrical integration, the BOSCH MOTORSPORT e-GoKart System componentshave to be connected via dedicated wiring harness.

All BOSCH MOTORSPORT e-GoKart System 12 V components (Vehicle Control Unit VCUMS 40, 12 V-Interface of the DC/DC converter, communication interfaces) have compon-ent specific sockets. All BOSCH MOTORSPORT e-GoKart System component interfaces (48V, 12 V supply and communication) provide mechanical protection against reverse polar-ity. The Charger Energy Storage CH 5-1.2 provides a connector interface with latchingmechanism for the connection to the 230 V grid.

When 48 V net is powered (during charging and driving) any short circuit in the 48 V wir-ing harness will damage the Energy Storages ES 5-2.4. The Energy Storage ES 5-2.4 in-ternal fuse will activate and cannot be replaced.

# For the electrical integration of the BOSCH MOTORSPORT e-GoKart System require-ments from Charger Energy Storage CH 5-1.2 [} 23] shall be considered.

3.4.2 Powertrain IntegrationThe BOSCH MOTORSPORT e-GoKart can be connected to the powertrain of the vehicle inseveral ways. The connection (e.g. belt or gearbox) is not in BOSCH MOTORSPORT scopeof delivery.

# The transmission (belt, gearbox) is not in the BOSCH MOTORSPORT e-GoKart Systemscope and shall be realized by the CUSTOMER.

3.4.3 System Validation# The transmission (belt, gearbox) is not in the BOSCH MOTORSPORT e-GoKart Systemscope and shall be realized by the CUSTOMER. The system software is programmed on atransmission ratio from 7.4 between the Power Unit PU 5-10 and rear axle.

3.5 System Performance

3.5.1 Charging TimeThe charging current is limited to 10 A per pack in order to optimize the lifetime of theEnergy Storage ES 5-2.4.

3 | System


Estimated Charging TimesCharging mode No. of 48 V Energy

Storages ES 5-2.4Charging current Estimated charging

time

Standard 1 10 A 217 min (3.6 h)

Standard 2 20 A (10 A / pack) 217 min (3.6 h)

3.6 System OperationThe BOSCH MOTORSPORT e-GoKart System is operated using the driver interfaces of thesystem. The system provides a feedback to the driver via the Display Unit DDU 18 consist-ing of a LCD screen and several telltales. The LCD screen offers several ways to inform thedriver about the current system feedback.

3.6.1 System ScreensThe Display Unit DDU 18 of BOSCH MOTORSPORT e-GoKart System provides 5 differentscreens:

1. Welcome Screen: Welcome message.

2. Start Screen: Vehicle active, Power Unit PU 5-10 locked.

3. Driving Screen: Power Unit PU 5-10 enabled.

4. Crawl Screen: Indication of driving direction for parking.

5. Menu Screen: Adjustable vehicle settings.

The Welcome screen is shown first at key-on (terminal 15). After system start-up, thescreen changes automatically to Start Screen. That screen shows how to enable drivingthe vehicle. In drive screen, the driver can select one of the three standard drive modes(GO, CRUISE, BOOST) differing in driving performance.

The Welcome Screen displays a welcome message for a short time. After that the StartScreen appears, indicating how to start the vehicle.

Illustration 7: Start Screen of DDU 18

The Driving Screen provides following information to the driver: time, ambient temperat-ure, selected drive mode, vehicle speed, power indicator bar, trip information, range andstate of charge of the Energy Storages ES 5-2.4.

# The driver shall not operate the system on public roads.

System | 3


Illustration 8: Driving Screen of DDU 18

Illustration 9: Menu Screen of DDU 18

Illustration 10: Setting Screen of DDU 18

4 | Component Description


4 Component DescriptionIn the following sections the components of the BOSCH MOTORSPORT e-GoKart Systemare described, including information about interfaces and handling notes for the respect-ive component.

4.1 Vehicle Control Unit VCU MS 40The Vehicle Control Unit VCU MS 40 is the main control unit of the BOSCH MOTORSPORTe-GoKart System. It controls all components and works as an interface between driver andvehicle.

The VCU MS 40 consists of an aluminum enclosure with a two chamber connector andmounting tabs. The housing has an integrated pressure compensation element.

Illustration 11: Vehicle Control Unit VCU MS 40

# Do not use the VCU MS 40 in vehicles different from applications intended for.

4.1.1 Technical Data– Maximum standby current 1 mA

– Power dissipation estimation of the VCU MS 40 depending on use case

– Weight approximately 500 g

– Outer dimensions approximately 123 x 142.2 x 43.1 mm

Component Description | 4


4.2 Energy Storages ES 5-2.4The BOSCH MOTORSPORT e-GoKart System is powered by 2 to 4 48 V battery pack(s)serving as energy storage of the system.

All Energy Storages ES 5-2.4 are passively cooled, with integrated temperature, current-and voltage measurement. Power switch and pre-charge circuit are controlled internally.The Energy Storages ES 5-2.4 have an aluminum housing with a solid plastic top andcover. The housing provides mounting bars for a fast and easy integration into the vehicle.

Illustration 12: 48 V battery pack “Energy Storage ES 5-2.4”

The design of the Energy Storage ES 5-2.4 is intended to provide a safe store of electricalenergy when operated and stored as advised within this document.

In addition to the documented precautions, safety-warning labels are located on theproduct, which serve to highlight specific dangers. It is important that labeling accordingto details below is understood.

# If any of the precautions or label explanations are not understood, or if there are anyfurther questions, contact BOSCH MOTORSPORT for guidance.

The safety information contained within this document may not include all regulations forlocal premises.

# It is therefore important that personnel working with a Energy Storage ES 5-2.4 shallconsider applicable local, federal and state regulations as well as the industry standardsregarding this product.

BOSCH MOTORSPORT is not responsible or liable for any damage or failure due to mis-handling or poor maintenance once received and accepted by the CUSTOMER. In the un-likely event of a cell venting, the Energy Storage ES 5-2.4 housing is designed to fail, in amanner to allow gases to vent from the cells to the atmosphere.

At the end of battery life, this product should be disposed in accordance with all relevantlegislations.

# The Energy Storage ES 5-2.4 described in this document shall only be used in the con-text of the BOSCH MOTORSPORT e-GoKart System to serve as a rechargeable energystorage. It is not intended to be used for any other third-party applications or outside thescope described in this document.



4.2.1 Technical DataKey data:

– Installed energy content 2.4 kWh,

– useable energy content 2.16 kWh,

– weight approximately <15 kg,

– dimensions approximately 100 x 260 x 364 mm +3/-3 mm,

– signal and power connectors with 20° orientation,

– passive cooling,

– CAN interface,

– Internal fuse for protection against short circuit current resulting from the 48 V net,

– robust aluminum case,

– versatile mounting possibilities.

Key data Battery Management System (BMS):

– Single pole shut-off switch,

– main fuse 125 A (non-replaceable),

– current measurement,

– temperature measurement,

– single cell voltage measurement,

– cell balancing,

– protection against cell overvoltage and under-voltage, overcurrent/short, over-tem-perature and under-temperature,

– CAN communication, diagnostic and status messages,

– thermal prediction (prediction of heating based on current consumption).

# After a crash event all components with nominal operating voltage of <60 V-DC or <30V-AC shall not be operated until it is ensured that no mechanical, electrical and thermaldeformation of components occurred. Seitenumbruch

4.2.2 InterfacesAn Energy Storage ES 5-2.4 provides three connectors:

– 6-pin connector for CAN communication,

– 48 V B- Terminal (M6),

– 48 V B+ Terminal (M8).



Illustration 13: Connectors of the Energy Storage ES 5-2.4

Main terminals are used for charge and discharge. Terminals are threaded, with M8 for the“+” (positive) connection and M6 for the “-“ (negative) connection.

Terminal screw connection is only approved for the following combination, which shall beused in vehicles:

Screw:

– B- Terminal: Stainless steel screws - M6x12 DIN 14580

– B+ Terminal: Stainless steel screws - M8x12 DIN 14580

Washer:

– B- Terminal: DIN 7092 - M6

– B+ Terminal: DIN 7092 - M8

4.3 Power Unit PU 5-10The BOSCH MOTORSPORT e-GoKart System is propelled by the e-GoKart Power Unit PU5-10.

The Power Unit PU 5-10 consists of a 5-phase air-cooled electrical claw-pole machine(electrically exited synchronous electric machine) and an air-cooled power electronic (DC/AC inverter) with an integrated microcontroller logic controller. The Power Unit PU 5-10can provide torque in forward and backward rotational direction. Since the Power Unit PU5-10 is air-cooled it has a preferred rotational direction. For series clockwise direction isavailable; counterclockwise is available as sample. Positive torque is denoted as boostmode. A negative torque is denoted as recuperation mode. The Power Unit PU 5-10 isscalable, that means the BOSCH MOTORSPORT e-GoKart System can be equipped with upto two Power Units PU 5-10.



Illustration 14: Power Unit PU 5-10

# Operation of the Power Unit PU 5-10 is only permitted in BOSCH MOTORSPORT e-GoKart System context, not for different applications than intended and agreed by BOSCHMOTORSPORT.

4.3.1 Technical DataThe Power Unit PU 5-10 provides two functions:

– Motor operation - convert electrical power from the vehicle electrical system intomechanical power and release to the drivetrain. Also denoted as boots mode.

– Generator operation - convert mechanical power from drivetrain to electric powerand feed it into the vehicle electrical system. Also denoted as recuperation mode.

Key data:

– 5-phase, electrically excited, claw pole synchronous machine with integrated inverter,

– air-cooled, cooling by integrated fans,

– integrated rotor position sensor,

– CAN interface for control communication.

# Given performance data refer to the capability of the Power Unit PU 5-10. Any limitationof the torque that could be necessary, e.g. limitation to 8.0 kW for electric Kart, is con-trolled by the Vehicle Control Unit VCU MS 40.

For cooling on pulley side, the air enters the Power Unit PU 5-10 in axial direction throughthe end shield. The air exits in radial direction through the openings at the perimeter ofend shield. For cooling medium clean air is recommended. For cooling on side of powerelectronic, the air enters the Power Unit PU 5-10 in radial direction through the heat sinkof electronic. The air exits in radial direction through the openings at the perimeter of endshield.

Sufficient cooling of the Power Unit PU 5-10 is only provided when the specified main dir-ection of rotation is maintained.



B+ bolt of the Power Unit PU 5-10 (terminal 40) provides 48 V power. It is connected tothe Energy Storage ES 5-2.4. All capacitors in 48 V net are pre-charged before the mainrelays of the Energy Storages ES 5-2.4 are closed in order to prevent potential damage ofcomponents. The capacitors in the Power Unit PU 5-10 have a maximum capacity of 3.5mF. The pre-charge current is limited to maximum 100 A. The current limitation is activeuntil the voltage difference between Energy Storages 5-2.4 and the Power Unit 5-2.4 isless than 2 V ( |UBat - UEdrv | <2 V ). The pre-charge process is controlled by the EnergyStorages Es 5-2.4 internally.

There is no inverse-polarity protection for the 48 V connection. The possibility of an in-verse polarity has to be prevented in the vehicle, which can result in non-reversible, un-known premature damage or a breakdown (also thermal) of the Power Unit PU 5-10.

Signals to control the Power Unit PU 5-10 are exchanged through the CAN- interface. TheCAN- wires are connected to the Power Unit PU 5-10 with a 6-pin connector. The VCU MS40 controls operation of the Power Unit PU 5-10.

In case of a detected fault in the Power Unit PU 5-10, the Power Unit PU 5-10 switchesinto idle mode, does not react to (torque) requests and indicates a fault via CAN. Theproduct's operating safety is only ensured if the permissible conditions are maintained.

# The CUSTOMER is responsible for appropriate usage of the Power Unit PU 5-10.

The electronics of the Power Unit PU 5-10 is supplied by the 48 V power. Any breakdownof the 48 V power results in switching off torque of the Power Unit PU 5-10.

The Power Unit PU 5-10 communication and control is realized using CAN. In case of adetected communication failure, the Power Unit PU 5-10 stops active torque generation.

If the limits of the Power Unit PU 5-10, e.g. voltage, temperature or common powerthresholds, are exceeded in any operation mode, requested output power will be providedunevaluated.

The Power Unit PU 5-10 has a self-protection functionality, which anytime may reduceoutput or input power up to complete power reduction to zero.

Use of high pressure cleaner at the Power Unit PU 5-10 (e.g. for cleaning) is not allowed.

4.3.2 InterfacesThe power interface of the inverter of the BOSCH MOTORSPORT e-GoKart Drive unit isshown in the following figure.

Illustration 15: Power interface of inverter



The power connection is realized via B+ and B- bolts designed as a threaded pin. The pro-tective cap covers phase connections and internal phase wires of the Power Unit PU 5-10.Correct wiring of the Power Unit PU 5-10 especially to the Energy Storages ES 5-2.4 is es-sential. Self-protection of the Power Unit PU 5-10 cannot be guaranteed for incorrect wir-ing. The pulley or coupling can be fastened to the e-GoKart Drive unit shaft by a nut. ThePower Unit PU 5-10 is mounted by isolated screws to accessory bracket(s) in the vehicle.Screws for mounting the Power Unit PU 5-10 and the accessory brackets are not in theBOSCH MOTORSPORT scope of delivery.

Illustration 16: Pulley mounting

4.4 DC/DC ConverterThe main function of the unidirectional DC/DC converter is the power transfer from 48 Vto 12 V. The DC/DC converter provides the supply power for all 12 V loads in the systemand charges the 12 V battery. For Europe the maximum charge voltage is 13.8 V depend-ing on the state of health of the 12 V battery and the ambient temperature.

Illustration 17: DC/DC converter



4.4.1 Technical DataThe dimensions of the converter are 68.9 x 140.0 x 29.5 mm. The weight of the converteris <400 g. For further information, see offer drawing.

Key data:

– Operating state: buck mode (input to output),

– rated power (continuous): 150 W,

– rated power (overload, 30 s): 180 W,

– maximum efficiency: >94 %,

– input voltage range: 35 to 55 V-DC,

– rated input DC-voltage: 48 V,

– prevent short-circuit from 48 V input to 12 V output inside DC/DC converter in anysingle failure case.

The output voltage on 12 V pin is actually between 13.5 V @ high load and 13.8 V @ lowload in normal condition. Output voltages <13.5 V can only occur in overload condition.The maximum continuous output current is 11.0 A. Enable of the DC/DC converter is con-trolled by the Vehicle Control Unit VCU MS 40.

4.5 Charger Energy Storage CH 5-1.2

Illustration 18: Charger Energy Storage CH 5-1.2

– Dimensions 179 x 317.75 x 90.5 mm

– Weight approx. 3.5 kg

– Sealed aluminum die-cast housing, built-in fan

– CAN control interface, compatible with BOSCH MOTORSPORT e-GoKart system

Illustration 19: System Context with the Charger Energy Storage CH 5-1.2



Electrical characteristics and maximum ratingsNominal output power 1,200 W

Single phase AC supply 47 to 63 Hz

AC power supply range 207 to 265 V AC

AC current max. 6.5 A

DC max. current 33 A

DC voltage range (tol.) 36 (+/- 1) to 54,6 V (+/- 0.26 V)

Efficiency >92 %

Power factor >0.98

Thermal derating above 40°C (linear decrease to 980 to 1,000 W at 60°C)

Illustration 20: Voltage/Current characteristic

Electrical interface, harness requirementsA cable harness between the Charger Energy Storage CH 5-1.2 and the Energy StoragesES 5-2.4 is included in the scope of delivery. This harness is divided in two portions:

1. Charger Energy Storage CH 5-1.2 - Connector

2. Connector - Battery Terminals

On the vehicle side a harness which is compatible with section 2) for all installable packsshall be used

The communication between the system components is realized via CAN bus. There is noneed for an external control.

# The communication lines shall be realized in accordance with ISO 11898 (impedance,shielding, twisted pair etc.)

The proposed setup does not require additional grounding. Any additional groundingmight lead to hazards or malfunction and is subject to agreement and validation withBOSCH MOTORSPORT.

Thermal integrationThe Charger Energy Storage CH 5-1.2 does not require any additional active cooling. Anintegrated fan operates at higher temperatures. If fan operation is impaired, charge per-formance may be limited but can continue. If mounted in a rack, appropriate heat convec-tion flow shall be ensured.

In order to ensure sufficient heat dissipation from the housing, the Charger Energy Stor-age CH 5-1.2 shall be splash water and dirt protected.

Heat radiation of adjacent components should not exceed the maximum permissible com-ponent temperatures as specified in the system TCD.

Installation environment must not constrain air circulation.



The housing temperature of the Charger Energy Storage CH 5-1.2 can reach temperaturesabove 60°C

Mechanical integration and Harness requirementsAll components shall be protected against drop and moving.

Rack installation via 4x M6 screws at the bottom plate of the Charger Energy Storage5-1.2.

Screws shall only be mounted into clean screw threads of the BOSCH MOTORSPORT e-GoKart System components.

No additional limitation concerning orientation and mounting angle

Illustration 21: Mechanical dimensions and interfaces

4.5.1 Usage

Intended UseBattery charging using a offboard fleet Charger Energy Storage CH 5-1.2 shall be handledby trained professionals (instructed persons) only. Their training has cover the relevantsubjects in this document and should be documented appropriately. The “battery swap”procedure on the vehicle shall also be performed by instructed persons but will not becovered in this document.

# Responsibility for correct pairing of batteries (same balancing level and SOH) is onOEM/User side.

The Charger Energy Storage CH 5-1.2 is designed to be continuously AC supplied. The ACsupply may have to be removed in error conditions. After establishment of the AC supply,the Charger Energy Storage CH 5-1.2 can take up to 6 s to be operational.



The Charger Energy Storage CH 5-1.2 can handle up to 2 Energy Storages ES 5-2.4 in par-allel operation.

A cable harness with two battery connectors may only be used in conjunction with twoEnergy Storages ES 5-2.4, i.e. no partial operation with an open terminal is permitted.

MisuseUsage of the offboard fleet Charger Energy Storage CH 5-1.2 as an on-board charger isstrictly prohibited. Off-board fleet Charger Energy Storage CH 5-1.2 and on-board char-gers are not interchangeable.

Input Voltages beyond 265 V AC may lead to irreversible damage of the components anduncontrollable behavior.

CAN communication interfaces must not be used by an external device to take control ofthe system.

Subsequent “hot un-/plugging” (i.e. removal of the DC connections during charge) willdamage to connectors and can lead to fatal malfunctions.

No additional loads other than the original battery packs may be attached to the ChargerEnergy Storage CH 5-1.2.

The maximum number of 2 attached Energy Storages ES 5-2.4 per Charger Energy StorageCH 5-1.2 must not be exceeded.

Modification of the cable harness is strictly prohibited, i.e. no different or additional con-nectors than originally equipped may be applied.

A cable designed for dual battery charge shall not be used to charge a single battery (pos-sibility of short circuit at open ended connector)

Chargers Energy Storage CH 5-1.2 may not be used in parallel on the DC side

The System of Charger Energy Storage CH 5-1.2 and Energy Storage ES 5.2.4 (includingcables) shall not be placed in an area with a distance to radio-transmitter (mobile phones,Wlan, Bluetooth, etc.) less than 1 m.

4.5.2 Functional descriptionCommunication is protected against errors in message transmission.

Batteries are inherently safe

A battery voltage less than 36 V will be treated as an under voltage condition and the sys-tem will be shut down. The normal operating voltage range is 36 to 54.6 V. At voltagesabove 54.6 V, an overvoltage condition will be detected in both the Charger Energy Stor-age CH 5-1.2 and attached Energy Storages ES 5-2.4. This detection will initiate a shut-down of the system.



User Interface

Illustration 22: User Interface states (E=Entry/Exit Wait state, A=Alarm state requiring AC reset)

Charge Initiation

CAUTION

Prerequisite: the system must be shut down!

The I/O pushbutton on the Charger Energy Storage CH 5-1.2 is used to initiate charging. Itmust also be used to terminate charging in order to limit current when disconnecting the48 V terminals.

Upon pressing I/O button, the Charger Energy Storage CH 5-1.2 will initiate a communica-tion handshake with the attached batteries. The handshake contains a detection of thenumber and state of attached the Energy Storages ES 5-2.4.

If all necessary conditions are fulfilled, the attached batteries will perform a precharge ofthe DC line and charging begins within 5 s.

Deep discharged packs (terminal voltage <32.5 V) will be detected and refused for charge.

The charging control contains an intelligent parallel operation of multiple Energy StoragesES 5-2.4. If possible, batteries are charged in parallel. If conditions for parallel operationare not met, batteries will be charged sequentially.

The batteries control the charge current depending on their state at any time.

During ChargeCharging time depends on the state of charge of the attached Energy Storages ES 5-2.4.The maximum charging current per pack is limited by the battery (default 10 A).



The charging status is indicated by a slow-blinking (2 Hz) LED. The color of the LED indic-ates the progress of the charge:

At ambient temperatures above 40°C, the output current and the power will be linearlydecreased

Charge InterruptionIf the I/O button is pressed during charging, the charging current will be reduced to a safeminimum and the batteries will be set in a safe state for disconnection.

The system is protected against hot plugging events by terminating the charge processimmediately in order to remove the voltage from the DC terminals. These events will bestored in a non-volatile memory for warranty reasons.

End of Charge, System ShutdownCharging has completed if the green LED is permanently on.

Before disconnecting the Energy Storages ES 5-2.4, the system shall be shut down eithermanually or automatically after 10 min (manual shutdown by pressing I/O button).

Shutdown can take up to 10 s.

Shutdown complete is indicated by the LEDs off.

Error conditionsIf an error is detected, the condition is signaled by a blinking LED pattern.

If an internal error has been detected, the Power I/O switch will not be effective any more.An AC disconnection is necessary in order to remove any voltage from the components.

If an error occurs subsequently, the Charger Energy Storage CH 5-1.2 should not be usedany more. The Charger Energy Storage CH 5-1.2 contains self-diagnostic capabilities. Basicdiagnostic information can be retrieved on the CAN.

Illustration 23: Alarm state logic

The device contains detections and protection from the following failures:

– Overvoltage

– Overcurrent / Short circuit / overload



– Feedback current from Energy Storage 5-2.4

– Reverse polarity

– Overtemperature

– Disconnect during charge (detection only)

4.5.3 Safety requirements– The system may only be operated by instructed personnel.

– Charging shall be supervised constantly. Charging is only permitted in well-ventilated,dry rooms.

– At voltages above 54.6 V damage of the Energy Storages ES 5-2.4 and the ChargerEnergy Storage CH 5-1.2 are possible.

– Dis-/assembly of cables and connectors is permitted without applied voltage only. Itmust be ensured that the Charger Energy Storage CH 5-1.2 is not AC connected andthat there is no voltage on the DC lines prior to installation.

– Connection of battery power terminals / comm. connector is only allowed after check-ing that there is no voltage at the battery terminals.

– The Charger Energy Storage CH 5-1.2 shall be switched off (=indication LEDs off) be-fore closing/opening electrical DC connections.

– Energy Storages ES 5-2.4 shall only be connected and disconnected in the ChargerEnergy Storage CH 5-1.2 OFF state (LEDs off).

– The setup shall be protected from avoidable impacts (drop, water, mechanical shock).

– Components that show visible damage must not be used.

– Components which show faulty behavior (e.g. tripping AC fuse) must not be used.

– If any component shows a different behavior than stated in this document, the corres-ponding BOSCH MOTORSPORT representative has to be informed before continu-ation of use.

– Error codes and instructions have to be available for any user.

– Any terminals which could exceed voltages of 60 V DC or 30 V AC shall be protectedagainst contact.

– Harness Connectors shall prevent reverse-polarity.

– Any Operation with disconnected terminals on AC and DC side shall be avoided.

– Components must not be opened (does not apply to removable terminal covers).

– Excessive or insufficient tightening torque as well as forgotten washers might lead toelevated contact resistances. Danger of overheating and fire!

– Electric interfaces shall not be exposed to mechanical forces or torques except formounting forces.

4.6 Display Unit DDU 18The Display Unit DDU 18 includes a display and telltales to provide system information tothe driver.



Illustration 24: DDU 18

Key data:

– High contrast and quality 4.4” black/white LCD dot matrix Display (320 x 240 pixel),

– elegant and progressive design using white font on black background,

– surface made of plain glass,

– robust interface for quick and easy assembly.

4.6.1 Technical DataThe display size is 4.4”, landscape optimized (viewing direction 6 h00). The display ismonochrome (white on black) with LCD dot-matrix (D)FSTN. It has a resolution of 320 x240 pixels, dot pitch maximum 0.28 mm. The active area is minimum 89 x 67 mm.

Supply voltage is 12 V nominal with reverse polarity protection. Minimum voltage is 8 Vand maximum voltage is 18 V.

The maximum current is 1.5 A @ 12 V. The quiescent current is <200 μA (target @ 12 V).

The display performs best in a temperature range from 25 to 40°C. If the display temper-ature is below 25°C due to low environmental temperature, the display will be heated in-ternally. During heating-up the display performance may be slightly limited in responsetime.

Overall Integration Requirements of e-GoKart System Components into the Superior Vehicle Context | 5


5 Overall Integration Requirements of e-GoKart System Components into theSuperior Vehicle Context

5.1 Electrical IntegrationFor the electrical integration the BOSCH MOTORSPORT e-GoKart System componentshave to be connected via dedicated wiring harness.

# During the electrical integration following order of integration steps shall be considered:

1. Connection B+ and B- cable to the Power Unit PU 5-10.

2. Connection of communication plug to the Power Unit PU 5-10.

3. Connection of B+ and B- cable to the Charger Energy Storage CH 5-1.2.

4. Connection of communication plug to the Charger Energy Storage CH 5-1.2.

5. Connection of the AC connector to the Charger Energy Storage CH 5-1.2.

6. Connection of B+ and B- cable to the Energy Storage ES 5-2.4.

# Assembly or disassembly of the cables is only permitted without applied voltage.

# The wiring harness routing of communication wiring shall consider that mechanicalloads to the BOSCH MOTORSPORT e-GoKart System component connector pins and tothe connector sealing are avoided while mounting as well as in use.

# All 48 V components shall be connected to a distribution point. This might be tractionnet power distribution unit (PDU).

# Usage of two cable lugs on top of each other at the terminals of the Energy Storage ES5-2.4 is not allowed. Parallel Energy Storages ES 5-2.4 must be connected via dedicatedrails or comparable solutions.

There is one common ground point of 48 V and 12 V ground located inside the DC/DCconverter.

# No additional ground connection is allowed.

# Maximum ground mismatch on 12 V ground net shall not exceed ±1 V.

# For reasons of electromagnetic capability the DC cable length between the Charger En-ergy Storage CH 5-1.2 and the Energy Storages ES 5-2.4 shall be ≤3 m.

# The housing of the VCU MS 40 shall be electrically isolated to the conductive vehiclechassis, in order to prevent electronic disturbance of the system and to increase the ro-bustness of the system in the case of failures, e.g. short circuits in the cable harness.

5.2 Mechanical IntegrationAll 48 V components, except for the DC/DC converter have screw connections for eyeletconnectors for the connection to the 48 V net. The DC/DC converter provides a dedicatedsocket.

# Screws to connect the wiring harness to the BOSCH MOTORSPORT e-GoKart System arein the responsibility of the CUSTOMER. BOSCH MOTORSPORT will propose appropriatescrew descriptions based on the BOSCH MOTORSPORT e-GoKart System component in-terfaces.

5 | Overall Integration Requirements of e-GoKart System Components into the Superior Vehicle Context


# At assembly or disassembly of the wiring harness to or from the interfaces of the BOSCHMOTORSPORT e-GoKart System, the used tightening torque shall not exceed the max-imum allowed torque, according to VDA specification.

# The screw connection for assembly shall be designed by the CUSTOMER so that anautonomous loosening is not possible over the whole lifetime of the BOSCH MOTORS-PORT e-GoKart System.

# The design of the screw connection shall be aligned between BOSCH MOTORSPORTand the CUSTOMER.

# Assembly or disassembly is only permitted without applied 48 V voltage. To avoid unin-tended autonomous power-up of the system, the 12 V battery shall be disconnected (ter-minal 30). In order to reach this condition during assembly, the 12 V battery shall be con-nected at the very end (terminal 30).

# Connection of the (partly screwed) power contacts (terminal 40, terminal 41) and com-munication connector (terminal 30, CANH, CANL, terminal 30C) is only allowed to be con-ducted in currentless and voltageless condition.

# Dismounting and removal of the wiring harness of the BOSCH MOTORSPORT e-GoKartSystem shall only be carried out by authorized and trained staff.

# Before dismounting the wiring harness, the key signal (terminal 15) shall to be switchedoff and a potential overshoot time shall be considered. To avoid unintended autonomouspower-up of the system, the 12 V battery shall be disconnected (terminal 30).

# Screws shall only be mounted into clean screw threads of the BOSCH MOTORSPORT e-GoKart System components. Before mounting the wiring harness, the respective compon-ent screw threads shall be checked for cleanliness.

# Unused pins in any connector shall be sealed.

# BOSCH MOTORSPORT components require longitudinally watertight cables, to avoidpropagation due to capillary effect. This means that all customer connectors and wiresmust be sealed in order to avoid trapped water within cables and connectors.

# Mating connectors (plugs, cable shoes) of the wiring harness shall be sealed, so that wa-ter intrusion into the connector is avoided.

# Electric interfaces shall not be exposed to mechanical forces or torques except formounting forces. Therefore a flexible cable connection is required.

# All electric interfaces of the BOSCH MOTORSPORT e-GoKart System shall be located inthe vehicle such that electrical connections are not permanently exposed to water.

# For connecting the battery only BOSCH MOTORSPORT -approved cable lugs, screws,and washers shall be used. BOSCH MOTORSPORT specification concerning the screw con-nection must be strictly observed. Excessive or insufficient tightening torque as well asforgotten washers might lead to elevated contact resistances. Danger of overheating andfire!

# Do not use any other combination of screw, cable lug, and washers. Do not leave outthe washers. Do not mount more than one cable lug onto a single battery terminal.

5.3 Component Integration Requirements

5.3.1 Vehicle Control Unit VCU MS 40The VCU MS 40 is designed for mounting at the vehicle chassis. In the BOSCH MOTORS-PORT e-GoKart it should be fixed on the HV-box.



# If the unpacked VCU MS 40 was dropped, it is strongly recommended not to use theVCU MS 40 further, because latent damages may affect functions or reliability.

# The VCU MS 40 shall have reached normal room temperature after the transport beforeanother use, particularly of flashing the software.

# Dew shall be avoided.

# Even though the VCU MS 40 is designed to fulfill IP6K9K, the VCU MS 40 shall not bepermanently exposed to water (no submersion).

# It is recommended to isolate the VCU MS 40 housing from the vehicle chassis electric-ally. This supports higher robustness of the system in the case of failures, e.g. short circuitsin the cable harness.

Power dissipation is conducted over cooling benches.

# The VCU MS 40 shall be fixed to the wiring harness box of the vehicle so that the ambi-ent conditions specified in this document are complied with.

# The VCU MS 40 shall be mounted at 4 mounting points in the vehicle.

# The mounting surface between all 4 mounting points shall be even with maximum dif-ference in parallelism of 0.5.

# There shall be a minimum distance of 50 mm from the VCU MS 40 to the outer surfaceof the vehicle (vehicle body). This is to ensure, that no external mobile transmitter (e.g. ina cellular phone) can disturb the system. In case that there is an internal mobile transmit-ter installed (e.g. in vehicle sharing concepts), the distance shall also be considered.

# The wiring harness shall be mechanically fixed next to the VCU MS 40 (maximum dis-tance 150 mm) such that an impact due to phase-shifted excitation of the wiring harnesscompared to the VCU MS 40 is avoided (e.g. at the VCU MS 40 screw-on plate).

# Relative movement between the wiring harness and the VCU MS 40 shall be minimized.Tension and pressure force on the connector caused by the wiring harness is not permiss-ible.

# The wiring harness shall not rub on neighboring parts.

# Potential loads onto cover and/or bottom of the VCU MS 40 housing resulting from themounting position in the vehicle shall be agreed on between the CUSTOMER and BOSCHMOTORSPORT.

# Impact of chemicals (e.g. oils, gasoline, detergents for cleaning, brake fluid, battery acid,etc.) should be minimized. Misuse of chemicals shall be considered.

5.3.2 Energy Storage ES 5-2.4BOSCH MOTORSPORT provides a standard solution for mounting the Energy Storage ES5-2.4 in the vehicle frame.

Illustration 25: Allowed mounting positions of the ES 5-2.4.



# The Energy Storage ES 5-2.4 shall to be mounted with the designated T-nuts M6 (BoschRexroth part no. 3 842 530 321) and associated springs (Bosch Rexroth part no. 3 842 516685), which are fixed in the notches of the housing, suchlike at the vehicle frame or at afixed vehicle equipment, that the battery housing is mechanically free of load and mech-anically stress-free in the vehicle! This means that no torque or bending moment is al-lowed on battery housing with regard to fixation points. Mounting in vehicle must allow compensation of the Energy Storage ES 5-2.4 housing tol-erances according to offer drawing, e.g. by elongated holes or compensation elements. Incase of other type of fixation, prior approval of BOSCH MOTORSPORT is required.

# The minimum tightening torque required to guarantee reliability of the screw connec-tion depends on the mounting location and is in the responsibility of the CUSTOMER. Re-commended tightening torque for M6 screws is 9 Nm and for M8 screws 15 Nm. In caseof any deviation from the standard solution, prior approval of BOSCH MOTORSPORT is re-quired.

# Do not connect the Energy Storages ES 5-2.4 electrically in series as potentially lethal DCvoltages may be present.

# In general, each Energy Storage ES 5-2.4 is to be installed so that sufficient airflow tocool the components is provided. Sufficient airflow will increase the system performancesignificantly.

# The Energy Storages ES 5-2.4 shall be mounted outside the passenger compartment.

# Environmental conditions shall be considered for vehicle integration position.

# In order to provide maximum possible protection against vehicle crash effects, the En-ergy Storages ES 5-2.4 of the system should be mounted outside crash-zones of thevehicle core.

# After a crash event the Energy Storages ES 5-2.4 shall not be operated until it is ensuredthat no mechanical, electrical and thermal deformation of components occurred.

# It shall be ensured that no adjacent components may penetrate the Energy Storage ES5-2.4 housing in a crash situation. The Energy Storage ES 5-2.4 specific stiffness character-istic needs to be considered.

# Fixation of Energy Storage ES 5-2.4 in the vehicle shall be designed in a way that all En-ergy Storages ES 5-2.4 are protected against effects of a vehicle crash.

# In order to drain gas in case of cell event, the CUSTOMER shall ensure an appropriateexhaust channel to the Energy Storage ES 5-2.4 compartment.

# The installation space around the battery shall be homogeneously ventilated but closedto direct head winds. Direct air flow can cause extremely inhomogeneous temperatures inthe battery which might cause safety and ageing issues.

# The mounting position of Energy Storages ES 5-2.4 shall be in a distance which is largeenough from a heat source to avoid any influence of heat transfer to the components.

# An installation position exposing the Energy Storages ES 5-2.4 to an environment tem-perature of >50°C may have a negative influence on the lifetime of the Energy Storage ES5-2.4.

# The Energy Storage ES 5-2.4 shall not be exposed permanently to an environment tem-perature >80°C.

This should be considered in the design of the installation position of the Energy StorageES 5-2.4 in the vehicle.

# The Energy Storage ES 5-2.4 housing can be connected to the vehicle metal chassiselectrical insulated or electrical conducted.



5.3.3 DC/DC Converter# In general, the DC/DC converter shall be installed so that sufficient air intake to cool thecomponents is guaranteed. Therefore at least 10 mm distance between the DC/DC con-verter and chassis parts is needed.

Insufficient airflow will lead to derating behavior and decreasing of lifetime.

# If the DC/DC converter is installed in chambers, sufficient air exchange between DC/DCcharger chamber and environment outside shall be considered.

# Appropriate protection should be taken to prevent each wire isolation from being dam-aged.

# The DC/DC shall be located in the vehicle such that electrical connections are not per-manently exposed to water.

# Wiring harnesses of input and output leads must be routed with a certain distance to re-duce a short circuit risk in case of mechanical damage of the wiring harness.

5.3.4 Power Unit PU 5-10The Power Unit PU 5-10 shall be installed under consideration of:

– Sufficient air intake to cool the components of the Power Unit PU 5-10 shall be en-sured,

– splash water protected installation position,

– dust-protected installation position,

– no critical radiant heat by other components,

– The Power Unit PU 5-10 needs to be protected against stone-chipping, mud and anyparts that could enter the Power Unit PU 5-10 which could cause a blocking (e.g. byundercoating)

The power connection is realized via B+ and B- bolts designed as threaded pins.

# The connection of B+ conductor needs to be realized by a cable shoe.

– Thread of B+ bolt M8 x 12,

– min. required contact face (cable lug to B+ contact face) 125 mm²

– min. required conductor cross section 35 mm²

– tightening torque: 18 to 25 Nm

– max. allowed fixation torque: 25 Nm

– max. allowed loosening torque: 32 Nm

– max. allowed cable length up to next fixation: each max. 300 mm

# The connection of B- conductor needs to be realized by a cable lug.

– Thread of B- bolt M8 x 12,

– min. required contact face (cable lug to B- contact face) 125 mm²

– min. required conductor cross section 35 mm²

– tightening torque: 18 to 25 Nm

– max. allowed fixation torque: 25 Nm

– max. allowed loosening torque: 32 Nm

– max. allowed cable length up to next fixation: each max 300 mm



# The terminals of the product are not protected against contact. Design measures at theconnecting lines on the vehicle side must be taken to rule out a short circuit between theterminals.

# The wires for the communication connector have to be fixed to the chassis at a distanceof about 100 mm from the Power Unit PU 5-10, preferably on the same base plate as thePower Unit PU 5-10.

# The Power Unit PU 5-10 shall be mounted electrically isolated to the vehicle chassis. Itshall be taken into account that connections with other metal parts e.g. gearbox, mayhave an impact on required insulation of the Power Unit PU 5-10 to the vehicle chassis.

Power Unit PU 5-10 with clockwise main direction of rotation:

– Nut: Left hand thread

– Screw: Right hand thread

The complete screwing unit is design for transmittable torques up to 56 Nm.

Illustration 26: Pulley mounting detail and example of pulley for toothed belts

# The following figure shows measures that shall be considered in the pulley or couplingdesign.

# For the transmission it is strongly recommended to use toothed belts.



Illustration 27: Manufacturing instruction for pulley assembly

# Tightening of the nut shall consider a torque AND angle limitation of:

– Step 1: Torque 40 Nm, -1 / +3 Nm

– Step 2: Angle 47 to 53°

with a torque limit of 98 to 140 Nm.

# In case of service or rework the nut shall be tightened with limited torque: 105 to 111Nm

# Tightening of the screw shall consider a torque limitation of 38 to 40 Nm.

The Power Unit PU 5-10 is mounted by screws to the accessory bracket(s) in the vehicle.Screws to mount the Power Unit PU 5-10 with the accessory brackets are not in theBOSCH MOTORSPORT scope of delivery.

# Only mounting points marked in Figure shall be used for the mounting of the PowerUnit PU 5-10.

# Before dismounting the Power Unit PU 5-10, the key (terminal 15) needs to be switchedoff and a potential overshoot time needs to be taken into account.



Illustration 28: Insulation from accessory bracket

# The nominal width of the bracket including all tolerances shall be max. 58.8 mm to en-sure that the Power Unit PU 5-10 can be mounted adequately.

Illustration 29: Mounting points of the PU 5-10

# The parallelism between vehicle support surface and the insulation bushing surfacemust be <0.05 mm.

Illustration 30: Parallelism of customer engine block (Insulation bushing not necessary)



# Maximum allowed shear force Fmax on point A during assembly and screwing is limitedby Fmax =180 N.

Illustration 31: Fixation A, Specification isolation bushings

# It is not allowed to place transportation appliance inside bushings for transportation ofthe Power Unit PU 5-10 out of package to assembly line in the plant.

# The screws are turned into the screwing bushes at slip ring end shield (screws are PowerUnit PU 5-10-ground). The screws are in responsibility of the CUSTOMER. A dielectricstrength of 1 kV is recommended.

# The CUSTOMER side of the contact surface of the isolation bushes shall be consideredwith a diameter of at least 19 mm. Furthermore, the contact surface must be even, freefrom burrs and free of prints.

# Screws to connect the wiring harness to the Power Unit PU 5-10 are in the responsibilityof the CUSTOMER.

# At assembly or disassembly of the wiring harness to or from the B+/B- bolts of thePower Unit PU 5-10, the used tightening torque shall not exceed the maximum allowedtorque, according to VDA specification.

# The screw connection for the assembly of the cable lug to the B+/B-bolt has to be de-signed by the OEM so that an autonomous loosening is not possible over the whole life-time of the Power Unit PU 5-10.

# The CUSTOMER shall ensure that this force limitation in considered by field service (ser-vice installations, etc.).

# Furthermore the design of the B+/B- cable and cable lug shall consider a permissibleforce application onto B+/B- connection <100 N.

5.3.5 Display Unit DDU 18The Display Unit DDU 18 can be mounted as stand-alone display to the handlebar or asan integrated display in the dashboard. The readability is depending on the mountingsituation, especially the mounting angle.

For mounting, there are 4 fixing points with M4 thread available.



Illustration 32: Mounting positions and dimensions of DDU 18

# Tightening torque of 1 Nm and the screw-in depths of 6 mm shall not be exceeded.Therefore, the length of the screws must be appropriate. Different screws lengths are pos-sible for different mounting locations.

# It shall be ensured that the tightening for mounting at the handlebar is designed in thatway, that loosing of the screws is prevented over lifetime.

Illustration 33: Mounting of faceplate onto the DDU 18

Wiring Harness instruction / Build up chassis | 6


6 Wiring Harness instruction / Build upchassisAssure that the components are fixed like shown in the following picture.

Display Unit DDU 18

Battery 1

Battery 2

Power Unit PU 5-10

Illustration 34: Kart chassis with fixed components

6.1 Implement the Components

6.1.1 48 V Wiring HarnessPlace a holder for the fuse on the black box with two M4 screws, washers and self-lockingnuts.

Illustration 35: 48 V wiring harness “Relay Mounting”

6 | Wiring Harness instruction / Build up chassis


Fix the black box in the kart chassis at four points as shown in the following picture.

Illustration 36: 48 V wiring harness “fixing Points chassis”

Connect the 48 V wiring harness with the components in the chassis.

– Power Unit PU 5-10

– Energy Storage ES 5-2.4 “1”

– Energy Storage ES 5-2.4 “2”

Use cable fixers to fix the wiring harness to the chassis.

On the following picture, you can see how to place the wires. The turquoise box in therear area symbolizes the black box. The red lines symbolize the cables of the 48 V wiringharness. They lead from the black box to the Power Unit PU 5-10 and the Energy StoragesES 5-2.4.

Illustration 37: How to place the wires

The following picture shows the wiring from the black box to the Power Unit PU 5-10,fixed after 50 to 100 mm.



Illustration 38: 48 V PU 5-10 wiring fixed on the chassis

Place the cables close to the structure of the kart as shown in the following picture.

Illustration 39: Cables placed close to the structure

Connect 48 V wiring with Energy Storage ES 5-2.4 “1”.

Illustration 40: How to connect the Energy Storage ES 5-2.4

Connect 48 V wiring with Energy Storage 5-2.4 “2”.



CAUTION

Moving parts can damage the wires.Fix the wires carefully at the chassis of the kart.

Illustration 41: Cables placed close to the structure

6.1.2 12 V Wiring HarnessImplement the 12 V wiring harness in the chassis after you have installed the 48 V wiringharness. On the following figure you see the 12 V wiring harness. All wirings are markedwith yellow labels.

Illustration 42: 12 V wiring harness “delivery state”



Connections of the wiring harness

Relay Housing

Middle / Top

Left Side

Right Side

Power Unit

Steering Wheel

Display

Front Side

Illustration 43: 12 V wiring harness “connector information”

– left side

– Battery 1 “batt_1”

– 12 V Battery “12V & GND”

– Remote HW “rte_spedlim”

– Brake pressure sensor “p_brake”

– middle/top

– Charger CAN “charge_CAN”

– Brake light “brake_sw”

– DC/DC converter “DC/DC”

– steering wheel

– Display Unit DDU 18 connector “SP/stear”

– Display Unit DDU 18 remote connector “rte_DDU”

– front side

– Acceleration pedal sensor “s_accped”

– Brake inductive sensor “p_brake”

– right side


– ON / OFF switch “open end wiring” (See Figure)

– Neutral / Drive switch “open end wiring” (See Figure)

– SOC-LEDs “LED SOC_1”; “LED SOC_2”; “LED SOC_3”; “LED SOC_4”

– Key switch “open end wiring”



– relay Housing

Please start the implementation with “relay Housing”. With this measure, the rough posi-tioning of the wiring harness is specified. After that, you can install all wiring in the chassis.

Left sideAfter you put the relay housing on its fixation, you start with the left side of the wiring. Tosimplify the wiring, lead the 12 V harness above the 48 V wiring harness as shown in thefollowing picture.



Keep the wiring close to the chassis and fix it after connecting all components every 50 to100 mm. Use cable fixer to prevent movement of the wiring and contact to moving parts.Start with connecting your 12 V supply with our open-end wiring.

Illustration 44: Left side wiring fixed on the frame

Middle wiring

Illustration 45: Charge CAN is connected to the HV wiring. Brake light and DC/CS are nor connected.

– Charger CAN “charge_CAN”

– Brake light “brake_sw”

– DC/DC converter “DC/DC”

Please fix the Anderson Connector direct with a screw on the chassis.



Illustration 46: Anderson Connector

Please implement the brake light wiring as described:

Pin 1: Kl.15 (12 V)

Pin 2: switched 12 V

Pin 3: GND

Right side

Illustration 47: Right side wiring

Fix all wiring for the right side with a cable fixer:


– ON / OFF switch “open end wiring” (see Figure)

– Neutral / Drive switch “open end wiring” (see Figure)

– SOC-LEDs “LED SOC_1”; “LED SOC_2”; “LED SOC_3”; “LED SOC_4”

– Key switch “open end wiring”



Illustration 48: ON/OFF switch, open end wiring

Illustration 49: At the old five wire cable the green wires were gray.

Fix the wiring on the emergency switch.

– Neutral: Wiring is not connected

– Drive: Wiring is connected

Neutral/Drive switch “open end wiring”

Illustration 50: How to connect the wiring on the LED

SOC-LEDs “LED SOC_1”; “LED SOC_2”; “LED SOC_3”; “LED SOC_4”

– +-wiring: White

– GND-wiring: Purple



Illustration 51: How to fix the wiring on the key switch

Illustration 52: Key switch "open end wiring"

Illustration 53: Power Unit PU 5-10-wiring fixed on the PU 5-10



Illustration 54: DDU 18 wiring fixed at the seat

It is important that the wiring intersection is mounted at the end of the seat.

– DDU 18 connector “SP/stear”

– DDU 18 remote connector “rte_DDU”

Illustration 55: DDU 18 connector should be fixed on the chassis via cable fixer.



Illustration 56: DDU 18 wiring should be fixed via cable fixer.

Please have a look on the wiring, it is not perfectly fixed. It can hook on the chassis.

+

-

Green: LED GND

Grey: Switch

Black: Switch

Purple: LED +

Illustration 57: How to solder the wiring on the Boost Switch

Please solder the open end wiring to the pins of the switch.

– Purple: LED +

– Green: LED GND

– Grey: Switch

– Black: Switch



Pin 1: yellow

Pin 2: brown

Illustration 58: How to solder the wiring on the Reverse Switch

Please solder the open end wiring to the pins of the switch.

– Brown: Switch

– Yellow: Switch

Illustration 59: Please fix the wiring on the steering wheel.

Illustration 60: Fix the wiring under the metal sheet.



Illustration 61: Fixed wiring under the metal sheet

Based on the Wiring intersection by the seat mounting, the wiring for the front has to befixed under the metal sheet.

– Acceleration pedal sensor “s_accped”

– Brake inductive sensor “p_brake”

Illustration 62: Fixed connector in front of the pedal system

6.1.3 Acceleration pedal sensorThe Acceleration pedal sensor should be mounted with the mark facing in wiring direc-tion.

– Mark = Point



Illustration 63: Position of the Acceleration pedal sensor

Illustration 64: Screws position

Check:

– Sensor mark position

– Screws position

Illustration 65: Acceleration pedal fixed



Illustration 66: Sensor turned in the final counter clockwise position

After the sensor is fixed, you should check the sensor position.

For the calibration, please use the BOSCH MOTORSPORT calibration adapter.

The following picture shows the needed parts:

Illustration 67: Multimeter with calibration adapter

Please connect the calibration wiring harness with the digital multimeter.

– GND (blue) connector in COM

– Sig. 1 (green) connector in „V“

– USB connector with a Laptop (5 V supply)

– Acceleration pedal connector with the acceleration sensor

Acceleration Pedal Position Sensor Signal

0 % 1,700 to 1,730 mV

100 % 2,850 to 2,900 mV

Table 1: Calibration Values



Check Signal:Please check the position several times.

– Press the pedal strongly and let it jump to the resting place.

6.1.4 Brake inductive sensorThe brake inductive sensor should be fixed on the mounting. A space of 2 to 3 mmbetween the sensor and the brake pedal mechanic (black metal) is necessary.

Illustration 68: Implemented brake inductive sensor

6.1.5 Pressure sensorFix the pressure sensor with a suitable tool. After implementation, the brake line must bevented before the first drive. At the end, connect the brake pressure sensor with the wir-ing harness (Label “p_brake”).

Illustration 69: Brake pressure sensor implemented in the brake liner

6.1.6 Switches and LEDsThe switches and LEDs are implemented in the right side wiring. All wiring harnesses aredelivered with open end wiring. Please cut the wiring on the right length and fix the com-ponents in the metal sheet on the chassis.



Illustration 70: Components fixed metal sheet

6.2 Vehicle Control Unit VCU MS 40At the end of the wiring harness implementation, the Vehicle Control Unit VCU MS 40 canbe fixed on the black box. Please use M3 screws with a washer and Loctite.

Troubleshooting | 7


7 TroubleshootingFor troubleshooting, please contact [email protected]

Bosch Engineering GmbHMotorsportRobert-Bosch-Allee 174232 AbstattGermanywww.bosch-motorsport.com

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