2022 Mini SE issue with charging 500 miles / new

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.

 

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.

 

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

 

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!

 

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…

 

Oops - yeah meant conTactor

 

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.

 

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.