EIVIL llls Electronic Throttle Gontrol (Siemens)

EIVILllls
Electronic
Throttle
Gontrol
(Siemens)
Training
Reference
Manual
BMWof NorthAmerica,Inc.
Service Training Department
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TABLEOF CONTENTS
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Corrporpnts
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4
Motors
.T h ro ttb P o si ti o n se nsor
.b cte rn a l S a fe $ P a th
.B a si cA d a p ti o n othf e PW G.
r EML ltlSControlModule
CruiseControloperation
Cylinder,BankSynelironization..
F a u l tR e co g n i ti o n /D i a gnosis
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11
.,,...12
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...15
..16
,.,...17
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INTRODUCTIOH
The EIIIL llls is a ne\ dy developedelectronicthrottle control system for the M73 V-12
engie. The EhdLllls was designedand developedby Siemensto BMW specifications.
The corrc+t of the EML llls systemremainsthe sameas the currentEMLsystemusedon
fle bfz0 eftgine.Thenew EML llls systemcontinuesto use two throttlevalvesand one
pedal pmition sensor (HruG).The EML llls control module regulatesthe positionof the
throttb valvesbasedon the input fromthe pedal positionsen$or.Thesemaincomponents
providethe samefunctionas the M70 BoschEML componentsdo,
In addition to throttle control, tfie main funstions of tlre EML llls include:
r ldle stabilization
by regulatingthe throttleopeningsat idle.
r Throttlevalvepositioningfor optimumstarting.
. Synchronization
of the cylinderbanks.
r Air volurnecontrolfor A$C/D$C operation.
r Cruise control regulation{the EML llls control module contains the new GR ll logic
introducedon the E38 740).
r Maximumroad speed limiting
The operationof the EML llls has been enhancedwith additionalbaekup {redundancy}
features.This helpsensurereliableoperationwhile rnaintaininga high levelof operational
safety,
The fault rnemoryof the EML llls controlmodule is nsw stored in an EFPROMso that
disconnectionof the batterywill not eraseany stor.edfaults.
The EMLllls systemis incorporatedintothe drivingmanagementsystemand is connected
to the CANlinefor signalinterfacingwith the DME,ASC+Tand AGS controlmodules.
Highlightsof tha new EML lll system include:
r Jlg EMLllls controlmodulecontainstwo separateprocessorsfor redundantcheckingof
inputsand output controls.
r Each throttle valve is now controlled by two separatestepper rrptors driving one rotor
and shaft(redundancyoperation).
2
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' Each DK assembly contains two feedback potentiometersfor throtile position
recognition.
r ThepedalpositionsensoriPWG)nowcontainsthreeinductivecoilsfor the pedalposition
input(redundancy
operation).
o Thehallsensorbrakepedalswitchis usedfor the brakepedalinput,
. Logicmonitoring
of pedal/throttle
valveoper.ation
no,longer
includesthe useof the g" and
17'switches.
. Theexternalsafetypathcircuitis a new design.
o E38 EML fault indicationis now handledby the Checkcontrolmodule,throughthe
instrument
clustermatrixdisplay,
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COMPONENTS
The rnaincomponentsof the EML llls systeminclude:
o The EML llls control modu'e
locatedin the E-box.
. JWothrotle (Dlg assemblies
mounted on each
manifold.
&
. One pedal position sensor (pWG) connectedto the acceleratorpedal
(witha separatekick-downswitch).
BRAKE
LIGI'IT
SWITCH
o Electronicbrakelightswitch,
KlCKDOWN
SWI'TCH
a
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' crui$e control main switch - mountedon the instrumentpanel.
Providesa switchedgroundinputto the EMLcontrolmodule.
(E38only)
r Mutti-Function
SteeringWheel- cruisecontrolswltchpad and the MFLcontrolmodule.
{E38only)
CRUISECONTFOIMAINSWffC}.{
CFTUISE
CONTROL
S\IIITCHES
EilIILIIIs
MFLCONTROL
MODULE
r Checkcontro'module - for activationof the
fauftwarningdisplay.
GF{ECK
EONTROL
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THROTTLEVALVE{DK} MOTORS
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Thethrottlevalveassemblyconsistsof the DK housingwith the throttlevalveplate,return
spring,drivemotorandfeedbackpotentiometers,
In contrastto the M70 - EMLsystem,the
EMLllls throttlevalveplateis drivendirectlybythe motor shaft.The geardriveis eliminated
whichaltowsfor a more precisecontrolof the throttleplate positioning,
A dualsteppermotorconfigurationis usedto drivethe throttleplate.Both steppermotors
arecontrolledthroughseparatefinalstagesin the EMLcontrolmoduleand operaieon the
onearmature.The finalstagesfor one steppermotorwindingsare controlledby one micro
processorwhile the second motor windingsare controlledby the secondprocessor.The
controlof the steppermotorstakes placesimultaneously
by each processor.
ROTOR
DUALPOTENNOMff'ER
A$SEIdBLY
MOTORSHAFT
RE-TURN
SPRING
THROTTLEPLATE
Thedualfeedbackpotentiometers
signalthe movementand positionof the throttleplateto
each pt'ocessor.The two potentiometershave separatepower and ground circuitsto
ensurethe reliability
of theiroperation.
This dual redundancysystem allows the EML llls to cCIntinueoperation,without driver
inconvenience,
if one steppermotor or controlcircuitmaffunctions.lf the self diagnosisof
the EML llls detects a Taultwith one of the steppermotor controls,it will switch off the
affectedcircuit and continueoperationfrom one motor control circuit. The fault will be
loggedand the EMLfaultwarningwill be displayedin the clustermatrix.
lf a fault occurs that cannot allowcontinuedoperationof the throttlevalve,the controtfor
that bank of cylinderswill be switchedoff as with the previousEMLsystem.
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$tepper Motor Gontrol
A digitatsquarewave signalis used to drivethe steppermotor of the DK assembly.The
duty cycleof the frequencyand triggerof the signalar€ changedto producethe magnetic
field requiredto movethe steppermotor rotor.
by four finalstages.Eachfinalstagehas
Eachset of steppermotorwindingsarecontr-olled
the abilityto switch betweenpower and ground to reversethe di'i.ectionof cunent flow
throughthe windings(trigger).This switching allowsthe magneticfield of the coitsto be
reversedallowingthe rotorto be drivenin eitherdirectionto positionthe throttleplateat the
precisesettingcalledfor by the FWGinput request'
Theiinalstagecontrolvariesthe duty cycleto controlthespeedof movementand position
of the throttleplate,
includes:
moJoroperation
for stepper,
Self Diagnoeis;ThescoBeof EML's selfdiagnosis
Both throttlevalvesare checkeddynamicallyprior to enginestading{part
of pre-startcheckwith KL 15 on).
Alleightfinalstagecontrolsper steppermotorwhen KL 15 is switchedon.
r Monitoring The supplyvoltagesfor all potentiorxeters.
position.
Throttlevalveset positionwith the feedbackpotentiometers
Comparingthe two poientiometersignals.
Comparingthe set pointsealculatedby each individuatprocessor.
The throttlevalveoperationfor OBDll checkingrequirements.
r Checking
CONDITIONSOF STEPPERMOTORCONTROL
$tarting: The EML llls control modulewill positionthe throttlevalvesto the optimum
opening for enginestart when it receivesthe KL b0 input overthe cAN line.
ldle: The FML llls programming
will maintaina stableidteby adjustingthe openingof the
throttlevalveswhenthe vehicleis at a standstill.
The EMLreceivesthe engineRpM signal
fromthe DMEcontrolmoduleoverthe CAN line.
The idlewill be stabilizedtor NC compr€ssoractivationto compensatefor the load of the
compressor.
The EMLreceivesTD and AC on signalsoverthe can line.
Decel Fuel Cutoff: Decelfuelcutoffis activatedbasedon the inputfromthe pedalposition
sensorand the engineRPMsignals.A highsignalis suppliedfrornthe EMLcontrolmodule
to the DMEcontrolmodulesfor the purposeof activatingdeceffuel cut off.
Theseinput signalsto the DMEcontrolmodulesar€ separatehard wire linesthat are also
usedfor the "safetyfuel cut off' featureof the EMLeontrol.
via :a
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THROfiLECONTROL
FORALL COND|IIONS
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THROTTTEFOStilON SENSOR(PWG)
The throttle position sensor uses an inductivecoil "oscillator"principlefor accelerator
positionrmognitioninput.The PWGconsistsof:
r Threeseparateinductivecoils.
r Onesoft iron core eccentric,attachedto the acceleratorpedalth.roughthe FWG shaft.
e One4, switch,for the externalsafetypath function.
Eaeh coil is suppliedwith an AC voltagesignal,at a specificfrequency,fromthe EML llls
controlmodule.As the pedatis rnoved,the eccentricshapeof the iron core,movescloser
to the PWGcoils.
This causes the
inductance of the
coifsto increasedue
to the concentration
of the magneticfield.
TODMEI
4" SWITCF{
Annfu*
AnnA/*
AA/*
BRAKE
LIGHT
SWTCH
@Y€
The increasinginductancein
the coil causesthe amplitude
of the AO frequeneyto be
reduced,
o
The amplitudeis decreasedlinearly.
as the pedalis presseddown.
The EML control modulemonitorsand processesthe changingamplitudeas the inpr:t
requestfor throttleopening/closing.
nMnr
n^n^r
nAnnr
The changingamplitudevalue is a measureof acseleratorpedal movement, The
FML
cnntrol module is programmedto recognizepedal movementfrom o. (idle)to ggP
woT)
basedon the changingvoltagesignal.
Thethree inductivecoils are used for redundancypurposes.All three signalsfrom
the pWG
are input and evaluatedby both processorsof the EML llls controlmodule.
lf one signalwere to fail, the operationof the EML system,from the driver'spercpective,
would not be affected.The EML llls controlmodulewould continueto funotion
from the
remainingtwo signals'The fault will be recognizedand storedin the fault memory
and a
lailurewarning messagewould be postedin the displaymatr.ix,lf a second signalwere to
fail,the systemwouldgo intothe failsafeoperationano th" EML llls controlmodule
would
stop respondingto the throttle input.The enginewill start but not run above idle.
This
secondfauft would also he stored in the fault memory.
10
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$ffERNAL SAFETY PArrI
The externalsafetypath circuitis maintainedto ensurethat the decelfuel cutoff is activated
if a fault occurs with the output control of the throttle motors causingthe engine not to
returnto idle.
The externalsafetypath eNistsfrom the electronicbrakelight switqh,throughthe 4'switch,
to the decelfuel cutoff inputsof the DMEcontrolmodules.
With the acceleratorpedal released{4'switch closed)and the brake pedal pressed,a high
signalis supplled(bypassingthe EML control module)to the DMF control modulesto
activatedeoelfuel cutoff.
w
40 SWTTCH
sp e cial
tool is no
longerrequired
to test the safety
pathcircuitfor proper
operation.A procedure
is listedin the diagnostic
pagesfor this purpose.
lt requires,slepping
on the accelerator,
< 4obut far enoughto display
an off idlecondition,with this displayedon the Dls sg,een,steppingon
the brakepedalwill displaythe decelfuel cut off requestto the DME.
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BASIC ADAPTION OF THE PWG
The PWGadaptionallowsthe EMLcontrclmoduleto learnthe idleand wide open throtle
lirnitpositions.This adaptionpt'oeedurernustbe carriedout in the followinginstances:
"ts4
r The EMLcontrol module is replaced
r The pedalpositlonsensoris replaced
r The F\ffG is disconnoctedwith the ignition,,ON!'
r A new variantcode is installedin the EML control module
r The DISdiagnosticproceduresrequestan adaptionbe canied out as part of the
troubleshooting
NOTE:The enginewill start but the throttlecontrolsystemwill not respondto inputsfrom
the PWG until this basic adaption has been compteted,The pr,ocedurefor the basic
adaptionis listedin the "SPECIALFUNCTION$"sectionof the DIS- EMLtest pages.
The adaptionprocedureis canied out with KL 15 switched"ON" and the engineuOFp,.
Drivingthe vehicleis no longer requiredfor pedaladaptionas with the M70 EML system.
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Etvtlill s coNTRoLMoDULE
The EMLllls controtmoduleis locatedin the E-Box.All controland safetyrnonitoring
functionso{ the EMLare backedup by redundantprocessing.Eachpair of the output
controlfinalstagesof the DK motorsis controlledby a separateprocessor,
TheEMLcontrolmodulecommunicates
withthe DME,ASC+Tand EGSbontrolmodules
overthe CANlinefor the followinginputs/outputs:
DMEConfiol Modules
' Enginecoolanttemperature
o Throttleposition
. NC status (ON/OFR
r Loadsignal{ti)for eachDME
. Enginespeed fl-D)
ASC+TGontrsl Module
AG$ Control Module
r Throttlevalveangle
r Throttlevalveincrease
r Throtilevalvedecrease
r Vehiclespeed
DMEI
DMEII
r Kickdown
r Transmissionrange/program
o ShiftCharacter:istics
AGS
'a/
CANBUSCONNECTOH
M0DULES
a[ows coNTRoL
TINKED
TOCANBUSTO CONNECT
TOONECENTMLCONNECTOR)
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ECMRELAY
(DMEMAINII)
OPEBATING
POWER
STEPPER
MOTOH1
PEDALPO$TNON
PC'IEI{JICI'IEIER
FOli'ERSGROUND
IDLESIGNAL
SAFIEYPATH
TOPMEI
TODMEII
$T,EPtrEB
.trrtotoRe
i;.
THffOTILE
HOUSING
2
STEPPER
Mo]ofi 1
ffi'w
STEPPER
MOT,OR2
EMLllls
CRUISECONTHOL
INDIOATOR
t
'4e
CHECKCONTROL
MODULE
FAULT
DISPLAY
CRUISE
CONTHOL
INPUTS:
IDLESIGNALTO
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E38SYSTEMS
SAFF|Y PATH
HIGHSIGNAL
FROMNArc
IDLESIGNIALTODME II
GR II MA IN
SWIICH
DIAGNOSIS
r
CANBUS
CRUISECONTROL
SWITCHES
MFLOONTROL
MODULE
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CRUISEGONTROLOPERATTON
All functionsof the cruisecontrolsystemare incorporatedin the EML llls controlmodule.
The cruisecontrolmain swlich is wireddirectlyto the EMLllls controlmodule.The multifunctionsteeringwheel inputs are directto the EMLthrougha separ:ateserialdata bus,
The EML control module regulatesthe operationof the cruise centrol by regulatingthe
positionof the throfilevalvesas it did in the past.The newcruisecontrollogicadoptedwjth
the GR tl E38 74Al are incorporatedin the EMLcontroltogic.
CRUISE
CONTROL
EML llls
swrTcHEs
MFLCONTROL
MODULE
TheEMLconlrolsthe cruisecontrolindicatorlempin the instrumentcluster.\ffhenthe main
switchis pressed,the indicatorlamp is illuminated.
The switching'fOFF'pr:ioritiesfor cruiseoperationare carriedover from the GR ll system.
The commandsfor cruisecontrolo:peration
are canied out accordingto the highestpriority
as follows:
5 - brakelightswitch 4 - transmission
in neutral3 - "OFF'request2 - SeVAccelerate
1 - Resume-
directlyfrom EMLcontrolmodule
from AG$ controlmoduleover CAN
from MFL steeringwheel
from MFL steeringwheel
from MFL steeringwheel
The new logicincorporatedintothe cruisecontrolinclude:
r Smootheraccelerationunderthe Hesumefeature.
. Dorrunshift
on decel (down hill)to provideenginebrakingeftuct.
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CYLINDERBANK SYNCHRONIZATION
automaticatly
on the EMLllls system.Thisensuresthat
Thethrottlevalvesares!/nchronized
bothcylinderbanksreceivethe sameairchargeandcreatesa smoothrunningengine.The
takes plaoe at an idle dur.ingthe purge system shut off time. The
synchronization
processlastapprox.'100seconds.
synchron2ation
d*
to takeplaceare:
Thetotalconditionsfor synchronization
r
r
r
r
.
r
ldling
Enginespeedbetween560 - 720 RPM
(DKidleposition)
Throttlevalvestopsrecognized
Loaddifferenceslde-to-sideno morethan .O4to 1O7o
controlmsdules
No fauttsin DMFJEML
Purgesystemshutdown
SYNCIiNON[Z[
qd
CAN BUS $IG}IAL:
LOAD SIGNALFOR
DME I IS 5% MORE
TI"IANTHAT OF DME II
The EMLcontrol module processe$the load signalsfrom the two DMEcontrol modules.lf
a differenceeXsts, the EML will adjustthe DK motorsto achieveequalair throughputon
both banks.
will not take placeand a fault
lf the load differenceis greaterthan 107o,the synchronization
is storedin the memory.
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FAULT RECOGNITION/DIAGNOSIS
The OBD ll regulationsrequirethat any fault with the EML llls system that can affect
emissionsmust tum on the "CheckEngineLamp"and be accessiblethroughthe OBD ll
read out connector,Thesefaults will also be stored in the fault mernoryof the EML llls
controlmodulefor accessthroughthe DIStest programs,
ThefailurewarninEof the EML llls systemis throughthe checkcontrolsystem(CCM)of the
E38.A fault rnessage fromthe EML controlmoduleis sent to the CCM and the message
will be posted in the matrixdisplayof the instrumentcluster.
The diagnosisprogramof the DISincludesthe "FaultSyrnptom"troubleshooting
pathsas
well as the Test Modules,ServiceFunctionsand ExpertModes introducedwith the E3g
740|
Diagnosisand troubleshootingshouldalwaysbeginwith the fauftsymptomtroubleshooting
mode.Followthe test modulesand diagnosticpath proviiCed
by the Dl$ Tester.
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BASICTROUBLESHOOTING
.
Alwayspersonallyverifythe customercomplaint.
'
Callup the faulted$ystemor appropriatetest scheduleto verifythe correctcontrol
moduleis installedin the car,
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r Followthe DiagnosticInformationSystem{DlS}on screeninstructionsand performall
teetsas sPecified'
r
Usethe Dl$ andfaultsyrnptomdiagnostioppceduresas trained,
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setfauttsin,memory.
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Systemproblemswhicheluded,iagnostie
procedures
mustbe broughtto the attention
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