2022 Mini SE issue with charging 500 miles / new

[Outagas]

Yes my Mini does this exact thing. Come home, plug in, get very long estimate to charge up. Then in about 10-15 seconds get Reduced Charging message.

Then I stop the charge (either in Mini Menu, L2 Menu, house circuit breaker, or just pull the connector off the car.)

Then I reconnect the car to start the charge again and the error message goes away and the car’s estimate to charge up is much quicker indicating the onboard system is using the normal higher power.

My L2 unit has an app that shows what it is doing. Here is a screen shot two sessions. First one, only ~3.6kW15amp then the next session after I restart ~7.2kW/32amp.

 

[Rexsio]

Yes my Mini does this exact thing. Come home, plug in, get very long estimate to charge up. Then in about 10-15 seconds get Reduced Charging message.

Then I stop the charge (either in Mini Menu, L2 Menu, house circuit breaker, or just pull the connector off the car.)

Then I reconnect the car to start the charge again and the error message goes away and the car’s estimate to charge up is much quicker indicating the onboard system is using the normal higher power.

My L2 unit has an app that shows what it is doing. Here is a screen shot two sessions. First one, only ~3.6kW15amp then the next session after I restart ~7.2kW/32amp.

View attachment 22375

At list is 2 of as as proof is something wrong with SE and we are not crazy but a dealer is not going to take care of this once they can’t replicate conditions in their dealers shops .I’m not electrician with degree of engineering but I reaserch a lot and in my opinion contactor in onboard SE charger is overacting taking charge AC from home wall charger convert to DC and if any spike in voltage occurs is closing flow of voltage to a car .at least is doing correct job.Those devices contactors react in nanoseconds to prevent damage to a car that’s why reduce charging occurs.This is not right Bmw should take this to consideration before **** happen and some of SE’s start burning our garages/ homes .I introduce my problem to geniuses from BMW concierge relations over a phone and I was not able to get phone / email to engineering BMW group from BMW headquarters to talk to someone knowledgeable to introduce my concern.

 

[Rexsio]

At list is 2 of as as proof is something wrong with SE and we are not crazy but a dealer is not going to take care of this once they can’t replicate conditions in their dealers shops .I’m not electrician with degree of engineering but I reaserch a lot and in my opinion contactor in onboard SE charger is overacting taking charge AC from home wall charger convert to DC and if any spike in voltage occurs is closing flow of voltage to a car .at least is doing correct job.Those devices contactors react in nanoseconds to prevent damage to a car that’s why reduce charging occurs.This is not right Bmw should take this to consideration before **** happen and some of SE’s start burning our garages/ homes .I introduce my problem to geniuses from BMW concierge relations over a phone and I was not able to get phone / email to engineering BMW group from BMW headquarters to talk to someone knowledgeable to introduce my concern.

 

[Outagas]

Met with Mini this morning including the service manager who came across the road from BMW. Told them about the 208 Volt vs 240 Volt issue and we tried charge session- no errors of course.

They’re keeping the car for a day or two anyway to dig around and see what they can see.

They also asked me to write up a report for them with as much detail about the issue as I have (including your ideas about commercial L2 voltage vs residential) and they will send it all off to BMW for review. I asked if they could get in touch directly with a factory engineer to discuss the issue and they said it’s never been done at their dealer level that they know of. Seems like lots of layers of administration.

I told them my biggest issues are:

> battery or other components are being damaged
> this issue wont be covered by warranty if it takes time to show damage
> inconvenience of having to manage the workaround and potential extra cost of other transformers at home that shouldn’t be necessary

Also your point about charging safety and fires is a great point and I’ll add that

So - we’ll see what happens. I’ll post back with any updates.

 

[Rexsio]

Exactly what you asking is happening is your SE acting the same way?unplug J 1172 plug again full Maximum charging.but what is explanation? I have no way to measure kW charging rate but a time of charging is cut in half from min. To max.means charging is on max.about 30-32 Amps max. And 16 Amps on min./ reduced charging.

Copy my responses on a subject and give this to your dealer as he is willing to forwarded to BMW and mention a contactor on onboard charger bc I think this is a week link of reduced charging

 

[Outagas]

Do you mean the contractor might be physically flawed or dirty?

 

[Outagas]

Interesting Update - Mini has discovered a fault in the a module called the KLE which sounds like a part of the battery charging and management system. They told me they were surprised to learn that there is actually one in stock in the area they will swap in to see if this cures the problem.

So naturally I start Googling BMW and KLE and what do I find….a Technical Service Bulletin for KLE errors on the i3. Remember that funky EV they used to make a while back? I’ve heard much of that EV architecture was evolved for the Mini SE. Not sure if the i3 issue is at all the same (the bulletin speaks only to reprogramming) but the component has thrown errors before. I also found a bulletin for the KLE unit on some 3 and 5 Series BMW hybrids. The direction in those cases is to replace the unit. There is discussion on some forums for those cars and sounds like the part is expensive new $4K+ but can be found online used for <$500 if you can find the right unit.

https://static.nhtsa.gov/odi/tsbs/2018/MC-10143558-9999.pdf

Anyway, they’ve got approval from HQ to try a replacement as the first concrete step. Won’t be able to do it for a couple weeks but I will keep reporting.

@Rexsio - maybe time to call your dealer again!

 

[Outagas]

Here’s what the unit looks like in the wild- at least on the 330 hybrid. Not sure if this is where one finds it on an SE…

 

[Rexsio]

Do you mean the contractor might be physically flawed or dirty?

Contactor not contractor the unit is filed with gas and completely seal and I will wait for your SE resolution than I get touch with dealers with all info if you put them on forum Thanks Rexsio

 

[Outagas]

Oops - yeah meant conTactor

 

[Rexsio]

Oops - yeah meant conTactor

I find out on English Mini F 56 forum at February 2021 dealers we’re replacing KLE units bc SE’s was not charging at all doesn’t matter what they try to fix.I mean forum in England.Replacement fix a charging essue

 

[Outagas]

Still waiting for my appointment for the swap. They asked for two weeks, then three more… Apparently swapping ppls summer tires back on are considered priority appointments this time of year.

 

[Outagas]

Alrighty gang - just got the car back after a two/day stay.

Work order says:
Internal Fault with KLE control unit
Replace to correct issue of Reduced Charge
Disconnect/De-energize High Voltage System
Drain HV battery coolant
Remove/Replace KLE Unit
Replace HV battery coolant
Reactivate High Voltage System
Program/Encode KLE unit
Clear Fault
Road test ok/Fault no longer present

As discussed they don’t have the correct voltage to determine if the fix worked but lack of fault is a good sign. Not sure why in two previous efforts no fault was noticed.

Definitely glad it’s a warranty repair owing to the high part cost.

Will monitor charging performance and report back.

If this is indeed the fix A huge, HUGE, vote of thanks to @Rexsio for putting me on to the 240 vs 208v commercial voltage issue. Armed with that the dealer agreed to dig a little deeper on my third visit vs just blame my home charging setup.

 

[Rexsio]

Alrighty gang - just got the car back after a two/day stay.

Work order says:
Internal Fault with KLE control unit
Replace to correct issue of Reduced Charge
Disconnect/De-energize High Voltage System
Drain HV battery coolant
Remove/Replace KLE Unit
Replace HV battery coolant
Reactivate High Voltage System
Program/Encode KLE unit
Clear Fault
Road test ok/Fault no longer present

As discussed they don’t have the correct voltage to determine if the fix worked but lack of fault is a good sign. Not sure why in two previous efforts no fault was noticed.

Definitely glad it’s a warranty repair owing to the high part cost.

Will monitor charging performance and report back.

If this is indeed the fix A huge, HUGE, vote of thanks to @Rexsio for putting me on to the 240 vs 208v commercial voltage issue. Armed with that the dealer agreed to dig a little deeper on my third visit vs just blame my home charging setup.

I’m very glad you responded to what issues you have I have exactly the same what I’m going through but I think your dealer went above what he try to fix like changing coolant in HV battery was overkill he must be good businessman to screw up BMW as he don’t have charging system set on 240 volts just 208 volts commercial he still don’t know if he fix an issue max charging versus reduce charging at your home . That fix must be like $10000 to BMW but I hope is going to work for you??? As I’m charging my car for past 2 months weekly on Charge Point public charging station like before I did 2-3 times bc I charge SE at home 100% I have any problems to charge my SE at all on public charging stations but in my garage once a while as I plug in SE I’m on reduce charge but as I’m unplugged and plug again I’m on MAX. Charge right away .Im not going to pursue any more to solved a problem I can live with it . As I hire license electrician to check my set up connections to panel which I did myself and voltage is 245 volts I just give up he said everything is perfect breaker wire size Hubbell outlets and I just send my Cleeper Creek charger to manufacture for checkup I’m done ! Car is perfect with range above 120 to 140 miles driving only in SPORT mode on 16 “ Hankooks.The same story with all this advance technology my solar system after 10 years working perfectly show me an error on inverter as insulation issue once at that day produced nothing but I cancel that error myself using Utube advice and 2 Months later no problem but the same electrician try to take me for ride take panels down to look for a problem .From 5.oo kW system I still produce 30kWh daily with good sunny weather that means in about 9 months a year my electric bill is 000 $ View attachment 22694 View attachment 22694

 

[Outagas]

Fantastic solar setup! I’d love to do that.

;-) And the dealer went above and beyond because I dragged the Service Manager over from BMW next door and asked that he, the Mini service advisor, and the service supervisor, and the poor guy they all pointed to and called “our resident EV expert” stand around the car for a convo vs just sending the car home. I presented your revelation, Rexio about 208 v 240 commercial and residential systems and could they please stop blaming my house panel and take another look. They did and voila - BMS (or KLE, or M-O-U-S-E….or whatever) had thrown a fault. My next worry was it would take six months for the part but I guess it’s what they use for the BMW hybrids and i3, i8 etc and had one next town over in a warehouse.
Re your comment about coolant change. I wondered about that too but it appears the KLE unit shares the same coolant routing so I guess they had to drain and refill.

Anyway - a couple weeks home and I get full or near full charging every plug in (so far anyway!)

 

[Rexsio]

Fantastic solar setup! I’d love to do that.

;-) And the dealer went above and beyond because I dragged the Service Manager over from BMW next door and asked that he, the Mini service advisor, and the service supervisor, and the poor guy they all pointed to and called “our resident EV expert” stand around the car for a convo vs just sending the car home. I presented your revelation, Rexio about 208 v 240 commercial and residential systems and could they please stop blaming my house panel and take another look. They did and voila - BMS (or KLE, or M-O-U-S-E….or whatever) had thrown a fault. My next worry was it would take six months for the part but I guess it’s what they use for the BMW hybrids and i3, i8 etc and had one next town over in a warehouse.
Re your comment about coolant change. I wondered about that too but it appears the KLE unit shares the same coolant routing so I guess they had to drain and refill.

Anyway - a couple weeks home and I get full or near full charging every plug in (so far anyway!)

View attachment 22787

I’m glad you solve that charging issues and in a future if I develop more problems your dealing with dealer will be my templet to deal with .Thanks for sharing @ Rexsio