Aftersales Training -

Participant's Workbook.
Basic concepts of the vehicle
electrical system.

BMW Service
The information contained in this Workbook is intended solely for the participants of this
seminar run by BMW Aftersales Training.

Refer to the latest relevant BMW Service information for any changes/supplements to the
Technical Data.

Information status: September 2007

Contact: conceptinfo@bmw.de

2007 BMW AG
Mnchen, Germany
Reprints of this publication or its parts require the written approval of
BMW AG, Mnchen
VS-12 Aftersales Training
Participant's Workbook.
Basic concepts of the vehicle
electrical system.
Notes on this Workbook

Symbols used
The following symbols are used in this Workbook to facilitate better
comprehension and to draw attention to important information.

3 contains information for better understanding of the described

systems and their functions.

1 identifies the end of a note.

Relevance:
In view of the constant further developments in the design and equipment
of BMW vehicles, variations may arise between this Workbook and the
vehicles made available as part of the training course.
The background material refers exclusively to left-hand drive vehicles.
The controls are in part arranged differently in right-hand drive vehicles
than shown in the graphics in the Workbook.
Contents.
Basic concepts of the
vehicle electrical system.
Training 1
Structure of atoms 1
Electrical voltage 3
Electrical current 9
Electrical resistance 12
Ohm's Law 15
Electrical power 18
Capacitors and electrical capacitance 20
Coil and inductance 22
 9
Participant's Workbook.
Basic concepts of the vehicle electrical system.
Structure of atoms
Electrons, protons and neutrons
All matter is made from approximately 100
different elements. The smallest building
blocks of these elements are atoms.
1 - Structure of a lithium atom
Index Explanation
1 Protons
2 Neutrons
3 Electrons
The model illustrated here is the Bohr atom
model. It shows the positions of electrons,
Assignment 1: Complete the illustrated models of atoms such that each model
represents an electrically neutral atom.
Solution: A)
B)
C)
protons and neutrons in relation to each other.
The model assumes that atoms are made up
of an atomic core or nucleus and an
atomic shell.
The atomic core is located in the centre of the
atom. It consists of protons and neutrons.
Neutrons are mass particles that exhibit no
charge. The protons are particles with a
positive electrical charge. The protons and
neutrons have approximately the same mass.
The atomic core or nucleus is charged
positively and contains virtually the entire
mass of the atoms.
The electrons are negatively charged
particles. The number of electrons in the
atomic shell equals the number of protons in
the core of the atom. The mass of the
electrons is approximately 2000 times less
than the mass of the protons or neutrons.
An atom is electrically neutral towards the
outside. The core and the shell of an atom
have the same number of electrical charges
(protons and electrons).
1
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Assignment 2: The copper atom has 29 protons in its core and 29 electrons
circling on 4 orbits about the core:
Orbit 1 ---> 2 electrons
Orbit 2 ---> 8 electrons
Orbit 3 ---> 18 electrons
Orbit 4 ----> 1 electron
Is copper a good or poor conductor? Give reasons for your
answer.

Solution:

2

Electrical voltage
What is voltage?
A voltage source is created by the separation
of positive charges on the one side and
negative charges on the other.
Voltage sources always have two poles of
different charge. The one side comprises the
positive pole with a deficiency of electrons
while the other side is the negative pole with a
surplus of electrons.
The electrons have a propensity towards
equalization between the negative and
positive poles, i.e. when both poles are
connected, the electrons flow from the
negative pole to the positive pole.
This propensity of the electrons to
achieve equalization is known as
electrical voltage.
The principle of electrical voltage can be
clearly illustrated using a vehicle battery as an
example.
2 - Positive and negative poles (terminals) of a vehicle battery
Index Explanation
1 Negative pole of battery
2 Positive pole of battery
9
The electrochemical processes in the vehicle
battery cause a separation of charges:
The electrons collect on the one side
(negative pole)
There is a deficiency of electrons on the
other side (positive pole)
Consequently, a difference in potential is
created between the poles, i.e. an electrical
voltage.
The voltage level depends on the difference in
the quantity of electrons.
When both poles of the battery are connected
by an electrical conductor with a defined
electrical resistance, the electrons will move
from the negative pole to the positive pole. An
electrical current flows for as long as there is
no difference in potential between the poles or
the current circuit is interrupted.
The following statements can be made about
electrical voltage:
Electrical voltage is the pressure or force
exerted on free electrons.
Electrical voltage is the cause of electrical
current.
Electrical voltage (pressure) occurs as the
result of the difference in charge between
two points or poles.
Formula symbol
The formula symbol for voltage is upper case
U.
Unit of measure
The unit of measure for electrical voltage U is
1 Volt (V).
3
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Voltage measurement
The following points should be borne in mind
when measuring with a voltmeter:
The type of voltage, i.e. alternating (AC) or
direct (DC) voltage must be set.
Initially, a larger measurement range should
be selected.
Observe polarity when measuring direct
voltage.
After measurement, the voltmeter should
be set to the largest alternating voltage
range.

3 - Digital multimeter for measuring voltage

Voltage is measured with a voltmeter. A digital

multimeter is often used for measuring the
electrical variables (voltage, current,
resistance).
A voltmeter is always connected in parallel to
the consumer, component or voltage source.

4 - Example: measuring voltage at the resistor R2

The internal resistance of the voltmeter should

be as large as possible in order not to influence
the circuit to be measured.
The momentary voltage is measured when
measuring at the voltage source.

4
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Assignment 3: Draw the voltmeter in the following circuit for measuring the
voltage at the resistor R1 and R4.
What is the value at the voltage at resistor R3?
Build up the circuit and measure the voltages.

Solution:

5
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Interconnection of voltage sources
The interconnection of several individual
voltage sources is known as a battery. When
the voltage sources are connected in series,
the total no-load voltage is equal to the sum of
the individual no-load voltages.
Utotal = U1 + U2 + U3
6
5 - A) Series connection of
voltage sources
B) Parallel connection of
voltage sources
Particular care must be taken in the case of
parallel connection of the voltage sources to
ensure that only the voltage sources with the
same individual voltage are connected in
parallel! When the voltage sources are
connected in parallel, the total no-load voltage
is equal to the sum of the individual no-load
voltages.
Utotal = U1 = U2 = U3
 9

Assignment 4: What values are measured in the following current circuits?

Enter the respective values in Volt.

7
 9

Solution: a)
b)
c)
d)
e)
f)

Assignment 5: Can the battery from a truck with a voltage rating of 24 V be used
to jump-start a passenger vehicle with a 12 V electrical system?
Give reasons for your answer.

Solution:

Assignment 6: How must the poles of the two batteries be connected correctly
for the purpose of providing a jump start?
Draw the circuit in the following illustration.

Solution:

8
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Electrical current
Directed movement of charge carriers
Electrical current is the directed movement of
charge carriers, e.g. free electrons or ions in a
substance or vacuum.
6 - Directed movement of free electrons.
The formula symbol for electric current is I.
The unit of measure for electric current is
ampere (A). Current is measured with an
ammeter.
7 - Measuring electrical current
Index Explanation
1 Switch
2 Ammeter
3 Resistor
The ammeter is always connected in series
with the electric load. For this purpose, the
wire of the current circuit must be cut to insert
the measuring instrument in the current
circuit. The current must flow through the
ammeter during the measurement.
The internal resistance of the meter should be
as low as possible in order not to influence the
current circuit.
The following points must be observed when
measuring with an ammeter:
Establish the type of current, i.e. whether
alternating current or direct current (AC/DC)
is flowing through the circuit.
Initially, the measuring range should be
selected as large as possible.
Observe the polarity in connection with
direct current.
After measurement, the ammeter should
be set to the largest possible alternating
voltage range.
9
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Clip-on ammeter
The clip-on ammeter is a further option for
measuring current. Measuring current with a
clip-on ammeter is of particular advantage
when currents > 10 A are to be measured. A
further advantage is that the current circuit
need not be opened for the purpose of
measuring the current.

8 - Measuring current with a clip-on ammeter

Index Explanation
1 Clip-on ammeter
2 Negative lead of battery

Assignment 7: Draw the ammeters in the following circuit for measuring the
current across resistors R1 and R4.
What is the value at the current across resistor R2?
Build up the circuit and measure the currents.

Solution:

10
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Assignment 8: With the aid of the Service Information 61 03 99 (474), measure

the closed-circuit current in a vehicle. Make a note of the
individual working steps and points of particular interest.

How high is the maximum permissible closed-circuit current in

BMW vehicles?

Convert the value into amps.

Why can a closed-circuit current be measured at all?

Solution:

11
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Assignment 9: The following illustrations show two possible directions of current flow.
What terms are used to describe them?
a)

b)

What is the reason for these different current directions?

Solution: a)
b)

12
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Electrical resistance

Electrical resistance of conductors

Electrical resistance is the impedance of The electrical resistance of a conductor is
electron migration through the lattice calculated with the following formula:
structure of the conductor. All conductors and
therefore all electric loads offer resistance to
the current. Three factors determine the
resistance of a conductor:
Material
9 - Formula for calculating the
Length electrical resistance of a
conductor
Cross section.
The longer a conductor, the higher its Index Explanation
resistance. R Electrical resistance in Ohm
The larger the cross section of a conductor, Resistivity in (Ohm * mm2/m)
the lower its resistance.
l Length of conductor in m
Different materials with the same dimensions A Cross section of conductor in
offer different levels of resistance. Each mm2
substance has a certain specific resistivity
Rho.

10 - Battery positive leads in the E90

Depending on the variant, different battery Copper cables are used on diesel engine
leads to the starter are used on the E90. vehicles. If aluminium leads were used, the
cross sections would have to be so large that
Battery leads made from aluminium are used
they would pose problems in terms of
on petrol engine vehicles.
package space and installation.
The advantages of aluminium are:
Low weight
Low costs
The disadvantage of aluminium is its poor
conductivity.

13
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Assignment 10: The battery lead to the starter has a length of approx. 5 m and a
diameter of 10 mm.
The specific electrical resistance of aluminium is = 0.0303
Ohm * mm2 / m.
The circular area is calculated using this formula: A = (d/2)2 *
Calculate the resistance of the battery lead.

Solution:

Assignment 11: What is the diameter of a battery lead of the same length but
made of copper assuming the same resistance of the lead?
The specific electrical resistance of copper is = 0.0178 Ohm *
mm2 / m.

Solution:

Assignment 12: The lead from the battery to the junction box has a length of
approx. 4 m and a cross section of 40 mm2. Another cable with a
length of approx. 2 m and cross section of 20 mm2 leads from the
junction box to the footwell module. A cable with a length of
approx. 2 m and a cross section of 5 mm2 runs from the footwell
module to the headlight. All three leads are made of copper.
Calculate the total resistance of these three cables.

Solution:

14
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Assignment 13: Two resistors are connected in parallel to the electrical supply
system of an E90 with a measured voltage UB = 13 V.

R1 = 1.2 kOhm
R2 = 3.9 kOhm

Calculate the total resistance.

Compare the total resistance with the individual resistances.

Solution:

15
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Ohm's Law

The most important law in electrical engineering

Ohm's law is one of the most important laws in
electrical engineering that describes the
relationship between voltage, current and
resistance.
The three basic variables of a current circuit
can be calculated with Ohm's law if at least
two of the variables are known.
Ohm's law can be expressed by the following
11 - The "magic" triangle
three formulae:
U=I*R The magic triangle can be used as an aid for
determining the different formulae of Ohm's
I=U/R law.
R=U/I The value to be calculated is crossed out. The
result is calculated with the two remaining
values.
A mental note of the word URI should be made
in order to remember the order of the values.

Assignment 14: A resistance of 6 Ohm is applied to a voltage of 12 V.

Calculate the current (amperage) with the aid of Ohm's law.

Solution:

Assignment 15: A current of 3 A flows through a 4 Ohm resistor.

Calculate the voltage with the aid of Ohm's law.

Solution:

16
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Assignment 16: A current of 4 A flows in a circuit at a voltage of 220 V.

Calculate the resistance with the aid of Ohm's law.

Solution:

Assignment 17: By way of example, a vehicle battery has an internal resistance

of 0.5 Ohm and a no-load voltage of 14 V. The heating element of
the seat heating has a resistance of 10 Ohm. A current of 3 A
flows when the seat heating is switched on.

How high is the voltage loss due to the internal resistance and
how high is the terminal voltage?

Solution:

17
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Assignment 18:

Build up the circuit.

Select the following values for the resistors:
R1 = 100 Ohm
R2 = 200 Ohm
R3 = 200 Ohm
R4 = 100 Ohm
Measure the voltage drop at all resistors and calculate the
currents through the resistors.
Note down your observations.

Solution:

18
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Electrical power

What is power?
Generally speaking, power is the ability to An unknown electrical variable can be
perform work within a defined period of calculated from two known electrical variables,
time. e.g.
The formula symbol for electrical power is P = U*I
upper case P and the unit of measure Watt
(W).
The mathematical relationship between
electrical power P, electrical voltage U,
electrical current and electrical resistance is
represented in the following diagram.

12 - Conversion circle for current I, voltage U, resistance R and power P

Assignment 19: The starter in the 330d has a power output of 2.2 kW. The starter
in the 330i has a power output of 1.4 kW.

Assuming a 13 V vehicle electrical system, calculate the

respective current rating.

Solution:

19
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Assignment 20: Remove the turn indicator side repeater from a vehicle.

Read off the power rating of the turn indicator side repeater.

What current flows through the turn signal side repeater?

What is the resistance of the turn signal side repeater?

Solution:

20
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Capacitors and electrical capacitance

Storage of electrical energy

Capacitors store electrical energy in an
electrical field. Corresponding to their design,
a differentiation is made between:
Non-polarized capacitors
Polarized capacitors
13 - Left: Non-polarized
capacitor
Right: Polarized capacitor
Capacitors are used for smoothing rectified
voltages and for the purpose of creating time
delays.
The storage capacity of a capacitor is referred
to as electrical capacitance. The unit of
measure for capacitance is Farad (F).
Capacitors used in practical applications have
values smaller than one Farad, e.g. 1 F = 10-
6 F (F = micro-Farad).
The value of the resistor, through which the
charge current of the capacitor flows and the
value of the capacitor are required for the
purpose of calculating the charge and
discharge time. The applied voltage has no
influence on the charging time.
Charging takes place faster the smaller the
capacitance of the capacitor C and the smaller
the resistance R.
The product of capacitor C and resistor R is
therefore defined as a time constant (tau).
=R*C
A capacitor charges or discharges at a rate of
63 % of the applied or charged voltage within
each time constant (tau). A capacitor is
almost fully charged or discharged after 5 time
constants.

Assignment 21: The following circuit for charging/discharging the capacitor is

given:

1 Voltage source
2 Switch
3 Ammeter
4 Resistor R = 470 Ohm
5 Capacitor C = 2200 F

Calculate the time required to charge capacitor C.

Solution:

21
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Assignment 22:

Five capacitors (1) connected in parallel serve as the energy

reserve for the rollover sensor in the E46. Each capacitor (1) has
a capacitance of 5600 F.
Calculate the total capacitance Ctotal .

Solution:

Assignment 23: These capacitors are discharged via two parallel-connected

electromagnets. Calculate the discharge time of the capacitors
when taking into account only the resistance of 10 Ohm of the
electromagnets.

Solution:

22
 9

Coil and inductance

switched off. An induced voltage is produced.

The formula symbol for inductance is L. The
unit of measure for inductance is H (Henry).
Typical values for coils are in the mH-range
(mH = milli-Henry).
The strength of the magnetic field of a coil
depends on:
14 - Electrical coil without iron - Number of windings N
core
- Current I and
A magnetic field is produced when current - The layout of the coil
flows through a coil. Coils are used in transformers, relays and
Coils store electrical energy in a magnetic electric motors.
field. The magnetic energy is converted back
to electrical energy when the flow of current is

Assignment 24: When current flows through a coil, a magnetic field is produced
about the coil.

Name three factors that define the strength of the magnetic

field?

Solution:

Assignment 25: Is the magnetic field of a coil weakened or strengthened by

inserting a soft iron core? Why?

Solution:

Assignment 26: Electric magnets rather than permanent magnets are used in
scrapyards to lift vehicles. Why?

Solution:

23
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Assignment 27: Build up the following circuit.

Two coils are arranged opposite each other on an iron core. The
coil that is connected to the voltage source is known as the
primary coil. A voltage U1 is applied to this coil and its number of
windings equals N1 = 500. The coil in which the current is
induced is known as the secondary coil. The voltage U2 can be
tapped off from this coil, its number of windings is N2 = 1000.
The ratio of the number of windings of the coils is the same as
the ratio of the voltages applied at the coils.

U1 / U2 = N1 / N2

The current ratio corresponds to the inverse of the winding

ratio.
I2 / I1 = N1 / N2
Calculate voltage U2, if U1 = 12 V.

Solution:

24
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