Cs Metier Ze Eng

SKILLS COURSE
ELECTRIC VEHICLE
TRAINEE BOOKLET
MECHANICAL TRAINING
DESIGN
SKILLS COURSE
LEGAL NOTICE
The technical information contained in these documents may only be used by specialists in the field of
automotive repair.
It is intended solely for use during repair and maintenance work on RENAULT vehicles by automotive
repair specialists possessing the necessary skills to perform such work.
RENAULT accepts no responsibility for work undertaken. All such work is the responsibility of those
performing it.
RENAULT accepts no responsibility for the use of technical information not corresponding to the most
up-to-date version issued by RENAULT.
TRAINEE BOOKLET
RENAULT Z.E.
SKILLS COURSE
GENERAL CONTENTS
ELECTRICAL LAYOUT
CHARGE
POWER WIRING
BATTERY
MOTOR AND TRANSMISSION ASSEMBLY
ELECTRIC MOTOR AND TRANSMISSION ASSEMBLY COOLING
THERMAL COMFORT
BRAKING
MAINTENANCE
TRAINEE BOOKLET
RENAULT Z.E.
SKILLS COURSE
ELECTRIC VEHICLE TRAINING
NOTES
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RENAULT Z.E.
SKILLS COURSE
ELECTRICAL LAYOUT
TRAINEE BOOKLET
RENAULT Z.E.
SKILLS COURSE
ELECTRICAL LAYOUT
INTRODUCTION
The electric vehicle has:
A 14 volt network
An EVC computer
A 400 volt network
The electric vehicle has a 14 volt electric network for:

Computers
Opening element management
Lighting
12 volt battery
Multiplex networks
TRAINEE BOOKLET
RENAULT Z.E.
Motor fuse and

relay box/
Protection and
switching unit
(UPC)
SKILLS COURSE
ELECTRICAL LAYOUT
MULTIPLEX NETWORKS
Global network
OBD
Vehicle
Multimedia
Opening
elements
Electrotech
Electric vehicles have one or more 14 volt multiplex networks, identical to the multiplex networks found on
Renault combustion engine vehicles. These multiplex networks use protocols such as CAN communication
protocols (for example: vehicle network) or even LSFT (for example: opening element network).
"Electrotech" network
Vehicle
The 4 computers present on this network communicate between themselves using a CAN protocol. The EVC
computer creates a gateway between the "Electrotech" network and the "Vehicle" network.
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SKILLS COURSE
ELECTRICAL LAYOUT
Traction battery charger

(BCB)
Converter assembly (PEB)
Electric vehicle central

management unit (EVC)
Traction battery computer

(LBC)
OBD
Electrotech
Multimedia
Opening elements
The EVC computer is developed based on another computer.
It has the same functions as the injection computer of a combustion engine vehicle.
TRAINEE BOOKLET
RENAULT Z.E.
SKILLS COURSE
ELECTRICAL LAYOUT
PASSENGER COMPARTMENT FUSE AND RELAY BOX
Electric vehicles have a passenger compartment fuse and relay box

(BFRH) identical to combustion engine vehicles.
MOTOR FUSE AND RELAY BOX / UPC

Motor fuse and relay boxes.
The motor fuse and relay box has the same
functionalities as on combustion engine
vehicles.
Protection and switching unit (UPC)

Identical to combustion engine vehicles.
THE EVC COMPUTER

Management of the 400 V / 12 V DC/DC converter
The EVC computer manages:
- Activation and deactivation of the function,
- The display of faults by the converter assembly.
Converter assembly
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Faults
EVC
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ELECTRICAL LAYOUT
Management of the 14 volt network
The voltage of the 14 volt network because it varies
according to the vehicle operating phases,
All of the faults related to the 14 volt network (undervoltage,
overvoltage, communication problem),
The display of warning messages on the instrument panel
in the event of a malfunction on the 14 volt and 400 volt
networks.
Management of the traction and cruise control/speed limiter

The EVC computer uses the converter assembly to manage the traction and
regulate/limit the speed setpoint of the cruise control/speed limiter.
Management of the charge

Junction box
EVC computer
The EVC computer actuates the charging of the traction battery via the charger integrated into the junction
box.
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ELECTRICAL LAYOUT
Management of the traction battery
The EVC computer manages the traction battery by actuating 3 relays (A, P, N):
- during the activation and deactivation phases of the vehicle,
- during the charging phases.
Pre-charging resistor
Management of the various instrument panel messages

The EVC computer manages the display of various messages on the instrument panel.
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Mileage counter with reset in kWh
Overall instant vehicle consumption in kW
Average consumption in kWh/100
Distance range
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ELECTRICAL LAYOUT
"INTERLOCK" management
The "interlock" function makes it possible to check that all of the 400 volt connectors are correctly connected.
This monitoring also prevents a voltage of 400 volts to be accessed by the user.
Insulation level
Description
The 400 volt network is completely insulated on the electric vehicle.
The EVC computer monitors the insulation level between the vehicle and the 400 volt network.
1st insulation fault
2nd insulation fault
The resistance between the battery and the vehicle chassis is measured.
The insulation fault sensor is located in the traction battery. It is the traction battery computer which sends
the impedance measurement via the multiplex network to the EVC computer.
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ELECTRICAL LAYOUT
Insulation level
1st insulation fault
This detection protects the equipment and the user in the event of a short circuit on the 400 volt network.
If a first insulation fault level is detected (>80 kOhms), a first orange service indicator light is displayed on the
instrument panel in order to warn the user.
2nd insulation fault
This detection protects the equipment and the user in the event of a short circuit on the 400 volt network.
If the fault reaches 40 kOhms, there is a danger for the user. Charging the battery is prohibited. The user is
warned by a red display on the instrument panel.
Earth strap
Earth straps are present on all components supplied with

400 volts.
Earth safety strap
In the event of insulation faults, the straps enable the 400
volt circuit to be closed via the vehicle body.
A procedure to check these straps is in place.
It is essential to refer to the technical documentation.
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ELECTRICAL LAYOUT
Preconditioning
The conditions to obtain preconditioning are:
When the electric vehicle is connected to the mains (charging) and charging is complete, the EVC computer
can request the thermal condition of the vehicle.
THE EVC COMPUTER MANAGES THE FOLLOWING FUNCTIONS:

Airbag
UCH
ABS
CAN network
Wire connection
LIN
Heater
Vacuum
pump
Electric coolant pump

(thermal comfort)
Additional resistor
unit
Electric coolant pump
+ valve (cooling)
EVC
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Air conditioning
compressor
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ELECTRICAL LAYOUT
THE ELECTRIC VEHICLE HAS A 400 VOLT ELECTRICAL NETWORK:
Vehicle mobility and charge
Junction box
400 volt network

Converter assembly
DC / DC
400 volt network
In an electrical vehicle, the

400 volt network is orange in
colour.
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ELECTRICAL LAYOUT
Junction box
Function
The Junction Box supplies the entire 400 volt network.
The Junction Box contains the battery charger.
The charger enables the traction battery to be charged.
The charger converts the alternating voltage of the external domestic
electrical network into 400 volt direct voltage in order to recharge the
traction battery.
Connections
Converter assembly connector
Battery connector
Resistor unit
connector
Charging plug
connector
Air conditioning
compressor
connector
Signal connectors
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ELECTRICAL LAYOUT
The converter assembly
DC / DC
The DC/DC converter enables the 400 volt voltage to be
converted into 14 volts in order to recharge the 12 volt battery
and supply the voltage to the standard electrical network
It replaces the alternator on a standard combustion engine
vehicle.
Inverter
Value (v)
Value (v)
Power inverter
Time
Time
The converter assembly contains a power inverter which supplies the 400 volt three-phase voltage to the
stator of the traction motor.
Immobiliser
The converter assembly forms part of the
immobiliser chain on the vehicle.
When the + after ignition feed is switched on,
the UCH requests authentication of the
converter assembly via the multiplex networks.
Converter assembly
(PEB)
EVC
The converter assembly is paired to the UCH

and cannot be swapped with another UCH for
a test.
UCH
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ELECTRICAL LAYOUT
Actuation
Three-phase
supply of the
electric motor
Electric motor
excitation
NOTES
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ELECTRICAL LAYOUT
SUPPLY LEVEL
The supply levels are:
+ Permanent
+ Timed feed
+ Accessories feed
+ After ignition
Automatic activation of functions
(LAP)
The UCH controls activation and deactivation

As soon as the computers that can be activated by the vehicle CAN networks are no longer active, they send
a message indicating that they are ready to be deactivated over the CAN network.
As soon as the assembly has responded favourably, the UCH sends a general deactivation request. When
this request is received, all the computers concerned are deactivated and cut their consumption on the 14
volt network.
There are 3 reasons why the UCH may activate the vehicle if the vehicle is deactivated:
"Customer" activation:
When the customer wants to use their vehicle (unlocking).
Technical activation:
Every 8 hours (for 10 seconds), the UCH activates the vehicle in order to assess the status of the battery.
The temperature is recorded by the traction battery computer and stored in the memory.
Technical activation:
Every 8 hours (for 10 seconds), the UCH activates the vehicle in order to assess the status of the battery.
The temperature is recorded by the traction battery computer and stored in the memory.
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ELECTRICAL LAYOUT
NOTES
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CHARGING
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CHARGING
Standard charging
Operation duration: 8 hours
Lead with EVSE
The charging lead equipped with the EVSE (Electric Vehicle Supply
Equipment) unit is available in 10 or 16 Amps.
Lead without EVSE
Using a lead without EVSE requires the use of a Wall Box in order to protect the installation.
This box has the same functionalities as the EVSE unit.
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CHARGING
Charging by quick-drop system
Operation duration: 3 minutes.
Accessible in certain countries.
Available on certain electric vehicles in the Renault
range.
Actuation
EVC
Speed
information
400 volt battery
Lock contacts
The EVC computer detects that the battery must be replaced in a Quick Drop station when the vehicle is
stationary and all of the locks are open.
At this point, all of the safety relays of the traction battery are disconnected from the rest of the 400 volt power
network.
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CHARGING
Charging by quick-drop system
To find out more
The traction battery is equipped with mounting
locks.
In After-Sales, these locks must be unlocked by a
special tool, MS1971.
Rapid charging
Operation duration: 30 minutes.
Vehicles equipped with the rapid charging
function have a special on-board charger.
NOTES
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CHARGING
CHARGING PRINCIPLE
Indicator lights
Vehicle socket
Lead
Industrial plug
EVSE
Indicator lights
10 A charge
[01]:[05]
remaining
During charging, the instrument panel is active and shows the remaining charging time.
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CHARGING
Step 1
When the vehicle is in sleep mode, connecting the
charging plug to the vehicle activates the UCH. The UCH
consequently activates the EVC computer.
The EVC computer activates the 400 volt network.
Step 2
The EVC computer sends a charging request to the
charger.
Step 3
The charger switches to fault finding mode in order to
ensure that its state can authorise charging (vehicle plug
connection status, traction battery relay status, etc.).
Once fault finding is complete, the charger sends the
information: charging ready.
Step 4
Charging commences. The charger follows the instructions sent by the EVC computer.
Step 5
Charging is complete when the 400 volt battery is recharged.
The charger performs fault finding once again. If everything is in order, the charger then sends the
instruction that the vehicle can be deactivated.
When there is no more communication over the multiplex network, the charger can enter sleep mode
status.
Vehicle socket
The socket on the vehicle side is a socket which meets the standard SAE
J1772 16-32A.
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CHARGING
Lead
3 wire lead + "control pilot" wire
3 wire lead
The lead has 3 wires:
The "control pilot" wire
- Live
The "control pilot" wire is a control signal which informs

the charger in the Junction Box about the maximum
current which can be supplied by the electrical installation
to which the vehicle is connected.
- Neutral
- Earth
EVSE unit
The EVSE unit renders the installation to be connected to the
vehicle safe by limiting the charging current.
READY:
GREEN
The EVSE (Electric Vehicle Supply Equipment) unit is

composed of:
- a circuit breaker,
CHARGE:
ORANGE
- a 30 mA differential,
- a bipolar switch,
FAULT:
RED
- an electronic stage which enables the switch to be

controlled when the 2 plugs are connected,
- an earth control.
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CHARGING
Industrial network plug
The industrial plug requires the use of an
adapter which differs according to the country of
use. This adapter facilitates the connection to a
domestic supply network.
NOTES
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POWER WIRING
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POWER WIRING
GENERAL INFORMATION
Two types of connectors
MAXIMUM CURRENT RANGE: 230

MAXIMUM CURRENT RANGE: 30 AMPS
AMPS
Voltage range: 400 volts direct current
IT IS ESSENTIAL TO MAKE THE VEHICLE SAFE BEFORE DISCONNECTING

ANY POWER CONNECTOR. THE VEHICLE MUST ONLY BE MADE SAFE BY
AN AUTHORISED PERSON.
Unlocking
Locking
Base
Slide
Area 2
to disconnect
Area 1 to
deactivate the
interlock
Catch locked/unlocked
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POWER WIRING
INTERLOCK
Interlock in closed position
Connector correctly locked:

400 volt wire continuity.
Connector incorrectly locked:

Interlock activated.
MAINTENANCE
Repairing forbidden / replacement compulsory
In the event of a fault on the wiring or on a power connector, it is essential to replace the "wiring and
connectors" assembly.
Repairing wiring and power connections is strictly

prohibited.
This information is found in Technical Note 6015A:
"Repairing electrical wiring".
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POWER WIRING
MAINTENANCE
Insulation tester (megohmmeter)
This device is used to measure the insulation of electrical equipment such as an electrical appliance, cables and
any equipment or installation likely to endanger safety in the event of a fault.
NOTES
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BATTERY
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BATTERY
COMPOSITION OF THE TRACTION BATTERY:
Power relay unit
Upper casing
Metal frames
Two stacks
Power circuit
Lower casing
Insulators: they protect

the modules from
vibrations and shocks
Weight: approximately 250 kg

Earth safety strap
Metal frames
Spacers
Metal rods
Bearing plates
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BATTERY
Stacks
Total voltage = Stack 1 (200 V) + Stack 2 (200 V) = 400 V
Each "stack" is composed of 24 modules fitted in series.
Stack 1
Stack 2
Type A module
Type B module
Composition of a module
Lithium-ion cells
Power connector
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BATTERY
Module
The cells are coupled in parallel then the sets of two cells are combined in series.
Power connector
Power connector
Intermediate connector
Cell
Voltage of one cell = 3.7 volts
Capacity of one cell = 34 amp-hours
Cathode
Anode
In a lithium-ion cell, the chemical reaction in the electrochemical accumulator is based on the presence of
lithium.
Lithium remains in an ionic state in the cell, thanks to the insertion of graphite into the negative electrode
(anode) and cobalt, manganese and iron sulphate into the positive electrode (cathode).
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BATTERY
POWER CIRCUIT
Transmit the current from the modules and stacks towards the power relays.
Bar plug
Busbar
Busbar
The "Busbars" enable each stack of modules to be connected to each other and direct the voltage towards
the power relays.
Bar plug
Bar plugs are interconnecting plates for the modules.
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BATTERY
ELECTRICAL SAFETY CIRCUIT
Mechanically and electrically isolates the power voltage leaving the battery.
Relay unit
Circuit breaker
Lockout
The traction battery relay circuit breaker is an insulation system which cuts the continuity of
the power circuit into two equal parts.
This system is involved in battery electrical lockout.
It is essential to be trained in order to work on the battery lockout device.
An interlock system informs the EVC computer of the presence of a circuit breaker and its
locking status.
Relay
Electromagnetic
relay
Busbar
Pre-charging relay
The safety circuit has:

- two plus and minus electromechanical relays,
- one pre-charging relay including a resistor which limits the inrush current when the battery is solicited.
These relays are controlled by the EVC computer.
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BATTERY
Actuation
Step 1
The EVC computer manages the traction battery by actuating 3 relays (A, P, N):
- during activation and deactivation phases of the vehicle,
- during charging phases.
Step 2
When the vehicle is switched on, relay A is actuated first.

The presence of a resistor on the circuit enables voltage peaks to be avoided during connection.
Step 3
Then relay N is closed.
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BATTERY
Actuation
Step 4
When the voltage in the 400 volt network reaches the voltage supplied by the battery, relay A is opened and
relay P is closed.
Step 5
In the event of problems on the 400 volt network, the EVC computer actuates the relays in order to isolate
the battery from the rest of the vehicle.
MONITORING LAYOUT
Traction battery computer (LBC)
Redundancy computer
(VMR)
Measuring circuit
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BATTERY
TRACTION BATTERY COMPUTER (LBC) AND DATA VERIFICATION
COMPUTER (VMR)
The role of the traction battery computer is to check and ensure that the voltage of the charging and
discharging modules is maintained.
The information processed by this computer enables the status of each module to be deduced.
The VMR computer is an additional computer. It enables redundancy for module charging and temperature
information measurements.
This redundancy guarantees the safety of the vehicle batteries.
MEASURING CIRCUIT
The measuring circuit collects the voltage of each cell and information from the temperature sensors.
The voltage of the cells is checked at three connection points of a module; "+", "-" and intermediate point.
All these measurements are sent to the traction battery computer and to the redundancy computer.
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BATTERY
CHARGING AND DISCHARGING A MODULE
VMR computer
LBC computer
Exchange
flow
The temperature of the stacks and modules is monitored using sensors.

The sensors are distributed over all of the modules.
The temperature criteria and the charging level influence battery wear.
FUNCTION OF THE LBC COMPUTER

Manage the operating range for one module: between 5 volts and 8.5 volts.
When the voltage of the module
reaches the minimum threshold,
the module enters an irreversible
damage phase.
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When charging, the module voltage

must not exceed 8.5 volts. Beyond
this value, there is a risk of thermal
runaway.
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BATTERY
SPECIFICATIONS OF THE KANGOO Z.E. BATTERY
Description
Centring devices
1300 mm
Secured to the bodywork by bolts

No cooling system.
300 mm
No quick drop system.
Weight: 260 kg
750 mm
Upper frame
Power relay unit
Power connector
Inner casing
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BATTERY
Casings
Earth straps are present on all components supplied with 400 volts.
In the event of insulation faults, the straps enable the 400 volt circuit to be closed via the vehicle body. A
procedure to check these straps is in place.
Earth safety strap
Stack 1: 24 modules
LBC computer
Stack 2: 24 modules
VMR computer
Circuit breaker
2 STACKS OF MODULES
2 stacks x 24 modules = 48 modules
1 module: 7.4 V and 68 Ah
Battery voltage: continuous 400 V
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BATTERY
SPECIFICATIONS OF THE FLUENCE Z.E. BATTERY:
The battery is positioned vertically in the luggage compartment.
800 mm
Protective casing
(steel)
Cooling system.
Quick drop system.
1200 mm
750 mm
Connecting and locking the battery

The battery is secured by 4 "Quick drop" locks on a frame which is fixed to the bodywork.
Circuit breaker
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BATTERY
Circuit breaker
The circuit breaker ensures that the battery is made safe.
It must be removed during an operation on the 400 volt traction chain.
It is involved with the vehicle lockout process.
When the circuit breaker is removed, it must be replaced by the lockout
tool equipped with its padlock.
The circuit breaker is located on the lower right-hand side of the battery.
It cuts the electrical continuity between the battery stacks and lowers
the voltage to 200 volts.
Quick drop locks

Lock
bolt
Belleville washers
2 retaining studs
The "Quick drop" locks ensure that the battery is secure.

Each lock is composed of:
- Two retaining studs on which the unlocking device is positioned.
- "Belleville" washers stacked on each other.
- A lock bolt ensuring quarter-turn unlocking and locking.
The bolt fits into a base containing an open or closed position switch which is fixed to the battery support
frame.
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BATTERY
Electrical wiring
Module stack

(LBC)
Battery data verification
computer (VMR)
Anti-tilt studs
The anti-tilt studs are positioned on the top of the battery casing.
Function: to avoid the battery from tilting forwards during a rear impact.
The anti-tilt studs must be adjusted in a battery repair centre.
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BATTERY
Module stacks
Stack 1
The battery of the FLUENCE Z.E. is composed of 3

"stacks" of modules. Each "stack" is comprised of 16
modules.
The "stacks" are arranged horizontally, one on top of
each other.
Busbars
16 modules per stack

48 modules in total (1 x 3)
1 module: 7.4 V and 68 Ah
Stack 2
Power connector
Stack 3
Power relay unit
Battery connector
CONNECTOR ON THE VEHICLE SIDE
CONNECTOR ON THE BATTERY SIDE
Actuation connector
Actuation connector
Centring devices
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+ and - power connector
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BATTERY
Battery cooling system
The cooling system is independent of the battery. This system, based on the "Peltier effect" principle, enables
the battery to cool when charging.
Battery air duct
Cooling system
Cold circuit fan
Hot circuit fan
Relay unit
"Peltier" cell
NOTES
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BATTERY
Battery cooling system (continued)
Cold circuit fan
Fresh external air
Temperature sensor
Hot circuit fan

Fresh air
circuit
External air
circuit
Battery temperature
sensor
Cooling fins
Hot air to the luggage

compartment
- +
Supply
The hot circuit enables the energy emitted by the "Peltier" cells to be released.
A "Peltier" cell subjected to a voltage supply produces both cold and hot air on another surface.
The fan of the hot air circuit draws in external air and releases it through an opening in the luggage
compartment.
This circuit enables the hot surface of the "Peltier" cells to be cooled. It contributes to improving the output of
the cold circuit.
The cold air circuit circulates the air in the battery in a closed loop system.
Cold air is produced when voltage is applied to each "Peltier" cell. When contact is made with the "Peltier"
cells, the temperature of the air gradually drops. The cold air is circulated inside the battery.
The cooling system enables the temperature to be lowered and maintained whilst the battery is charging.
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BATTERY
Battery cooling system (end)
14 V
Battery
temperature
Temperature sensor
Power signal
Cold circuit
fan
Charging
time
Command signal
Hot circuit
fan
+ Accessories
f d
Command signal
Power signal
Cell
PELTIER
14 V
Control signals
Vehicle
stationary
Temperature > Conditions for stopping battery cooling:

25C
- Battery temperature less than 15C,
Battery
charging
- Operating duration of 8 hours,
Activation conditions
- Difference between the battery temperature and the external temperature greater than
10C.
NOTES
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BATTERY
REPLACING
WARNING:
The battery must be replaced by an authorised electric vehicle specialist who has
been trained by RENAULT.
REPAIRING
WARNING:
It is prohibited to open a battery in an After-Sales workshop.
No internal or external operations must be performed in After-Sales.
If a fault is noted, the battery must be removed and sent to a specialist workshop.
This authorisation does not exist in the Renault network.
Specific authorisation is required for performing live work to repair a battery.
NOTES
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GENERAL INFORMATION
Composition of the motor and transmission assembly
Junction box
Battery charger
Motor and transmission assembly

support
EVC computer
Battery charger
Identification
Reduction gear
Electric motor
Multifunction sensor
Weight of the motor and transmission assembly
130 kg
JUNCTION BOX
The junction box enables voltage from the battery to be distributed to the components of the electric motor
and transmission assembly.
Battery
Converter assembly
Additional resistors
220 volts
Air conditioning compressor
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GENERAL INFORMATION
Motor and transmission assembly support
The support houses the components of the motor and transmission assembly.
Straps are used to ensure the continuity of the earth between the components of the electric motor and
transmission assembly and the bodywork.
Earth safety straps
Earth straps are present on all components supplied with 400 volts.
In the event of insulation faults, the straps enable the 400 volt circuit to be closed via the vehicle body.
A procedure to check these straps is in place.
CONVERTER ASSEMBLY
Description
Supply of the 3
stator phases
Rotor supply
Multifunction connector
(Under the converter)
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CONVERTER ASSEMBLY
Layout
The voltage converter function enables the accessories battery to be recharged.
400 V
CAN
14 V
DC/D
Electronic
Management
Stator
Power
inverter
Current
sensors
Excitation
Phase 1
Phase 2
Phase 3
Rotor
Position
sensors
+ after
Power inverter
volts
volts
400
400
Time
Power
0
Time
The power inverter function enables the 3 phases of the stator to be supplied.
The power inverter converts 400 volt direct current voltage into 400 volt three-phase voltage.
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Current sensors
A current sensor is used to measure the current on the three alternating phases.
The magnetic fields generated in each wire are measured by Hall effect sensors.
This measurement ensures current regulation over the various phases.
An additional sensor is present on the rotor excitation.
Power inverter
Current sensors
To electronic management
Excitation
EVC COMPUTER
The electric drive system is managed by the EVC computer.
Like an injection computer, the EVC computer receives information from the various sensors in
order to supply the electric motor.
ELECTRIC MOTOR
Description
The rotor shaft has

splines.
The stator
The rotor
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The electric vehicle uses synchronous type technology.

Value (V)
Time
The three-phase supply of the stator creates a rotating magnetic field which drives the rotor.
The rotation speed is proportional to the frequency of the three-phase supply.
Excitation
The excitation unit ensures the excitation of the electric motor rotor.
The excitation actuates 400 volts direct current to supply the rotor
winding. The brush/ring system enables current to flow through to
the rotor.
Position sensor
The sensor is located between the motor and

the reduction gear.
The sensor reads the position on a fixed
target on the rotor.
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The position information

is sent to the converter
assembly.
The angular position enables the

magnetic field of the stator to be
phased with the magnetic field of
the rotor.
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SKILLS COURSE

Identification
Motor type:
5: Coiled synchronous
rotor
4: Permanent magnet
synchronous
3: Asynchronous
Motor suffix:
400
Motor family
A
B
C
Cubic capacity
M
G
The multifunction sensor, located on the gear selector of the reduction gear, informs the computer about the
position of the gear lever.
The sensor sends information
about the following positions:
-
Park
Reverse gear
Neutral
Forwards gear
Speed reducer
The reduction gear transmits the rotation speed of the motor to the differential.
The rotor and reduction gear are connected by a gear assembly.
Rotor output pinion
Differential
Gear reduction pinion
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Description
The current varies according to the pressure on the pedal: At "full load", the current is at maximum.
FORWARDS GEAR
ACCELERATION
OFF REGULATOR
Current
Frequency
Frequency is proportional to vehicle speed; the higher the speed, the more the frequency increases.
FORWARDS GEAR
ACCELERATION
REGULATOR ON
Current
Frequency
The recoverable energy depends on the profile of the road.

FORWARDS GEAR
DECELERATION
OFF REGULATOR
Current
Frequency
In reverse travel the supply of the phases is inverted.

REVERSE GEAR
Current
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ACCELERATION
OFF REGULATOR
Frequency
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SKILLS COURSE
ELECTRIC MOTOR AND TRANSMISSION

ASSEMBLY COOLING
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ELECTRIC MOTOR AND TRANSMISSION ASSEMBLY

COOLING
PRESENTATION
THE ELECTRIC VEHICLE COMPONENTS TO BE COOLED ARE:
Junction box
Converter assembly
Motor/reduction gear
assembly
DESCRIPTION
Expansion bottle
Fan assembly
Solenoid valve
Electric charging pump
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Electric driving pump
62
SKILLS COURSE

COOLING
EXPANSION BOTTLE
The expansion bottle cap is identical to that on combustion engine vehicles.
SOLENOID VALVE
Description
Track 2 (output)
Track 1 (input)
Track 3 locked internally
The EVC computer actuates the solenoid valve during the various operating phases: when charging and
when driving.
The solenoid valve is open when it is not supplied: tracks 1 and 2 communicate with each other.
Electrical specifications:
- Nominal power: 20 W at 13.5 V
- Consumption when changing position: 30 W at 13.5 V.
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COOLING
ELECTRIC CHARGING PUMP
Location
Input
Outlet
Normal mode:
The charging pump is actuated by an OCR signal according to the coolant temperature.
Defect mode:
If the control signal is lost, the pump operates at maximum speed to ensure cooling.
Actuation
OCR control
Power supply
The EVC computer actuates 2 coolant pumps, the solenoid valve and the UPC relay control.
The UPC supplies the fan assembly.
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COOLING
FAN ASSEMBLY
The fan assembly originating from the combustion engine version

has two or three speeds depending on the vehicle.
The cooling speeds are ensured by several relays and a resistor
unit.
The relays are located in the UPC and the motor fuse and relay
box.
NOTES
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COOLING
MANAGEMENT OF THE COOLING CIRCUIT:
"Driving" actuation
EVC
The driving pump is activated
by the EVC computer.
The motor and transmission
assembly is cooled.
Solenoid valve
Charging pump "OFF"
55C
Charging pump "ON"
"Charging" actuation
EVC
The driving pump is not
activated.
The solenoid valve is closed
because it is supplied.
The charging pump is
activated by the EVC
computer.
Solenoid valve
The Junction Box is cooled.
Charging pump "OFF"
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Charging pump "ON"
55C
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COOLING
"Driving pump malfunction" actuation
EVC
The driving pump is
inoperative so the charging
pump takes over and the
solenoid valve closes.
Solenoid valve
"CLOSED"
Charging pump
"ON"
Charging pump
"MALFUNCTION"
55C
"Charging pump malfunction" actuation
EVC
The charging pump is
inoperative so the driving
pump takes over and the
solenoid valve remains
closed.
Solenoid valve
"CLOSED"
Driving pump "ON"
55C
Charging pump "MALFUNCTION"
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COOLING
NOTES
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THERMAL COMFORT
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THERMAL COMFORT
GENERAL INFORMATION
There are 3 types of passenger compartment cooling system:
- External ventilation,
- Manually controlled air conditioning,
- Automatically controlled air conditioning.
The system is composed of a "hot" loop to ensure the heating function.
Differences between an electric motor and a combustion engine
TRAINEE BOOKLET
A motor energy recovery circuit.
A circuit dedicated to thermal comfort.
A compressor driven by the motor.
A compressor driven by an electrical source.
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THERMAL COMFORT
NEW FUNCTIONALITIES
They enable thermal comfort and battery range to be optimised.
Standard air conditioning

For vehicles equipped with a standard heating
system only, a new version allows the heating to be
inhibited via the "maximum cold" position
Automatic air conditioning
The "SOFT" mode on the instrument panel is changed to an "ECO" mode.

This mode limits the electrical consumption of the air conditioning system.
Pre-conditioning
For a standard heating system, it is possible to anticipate passenger compartment heating using the
preheating/cooling function.
For a vehicle with climate control, it is possible to anticipate passenger compartment heating or cooling using
the preconditioning function.
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THERMAL COMFORT
Heating by auxiliary heater
A switch enables an auxiliary heater to be controlled.
HEATING CIRCUIT
The heating circuit is separate from the motor cooling circuit.
The heat produced by the combustion engine is not available on an electric vehicle. The electric vehicle has
other systems to ensure the "heating" function of the passenger compartment.
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THERMAL COMFORT
COMPONENTS OF THE HEATING CIRCUIT
Expansion bottle
Heater matrix
Temperature
sensor
Water pump
Additional resistor unit
Bleed screws
ADDITIONAL HEATING EXPANSION BOTTLE

Identification
This tank is only used for the heating circuit. It has the same functions as those used on
the cooling circuit of a combustion engine.
The cap is the same as that used on the cooling circuit of a combustion engine. It has
the same degassing setpoint and the same symbol.
Location
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THERMAL COMFORT
HEATER MATRIX
Identification and location
A heater matrix is used to transmit the heat into the passenger compartment.
SELF-CONTAINED HEATING COOLANT PUMP

An electric pump is used to circulate the fluid through the system.

An indication on the pump displays the circulation direction of the fluid.
Actuation
The speed of the electric pump is controlled by a control signal.
The supply voltage of the pump is 14 volts.
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THERMAL COMFORT
BLEED SCREWS
There are two standard bleed screws.
To find out more

The coolant used for the heating circuit is the same coolant used on
combustion engine vehicles.
TEMPERATURE SENSOR
The temperature sensor is an "NTC" type thermistor (Negative
Temperature Coefficient).
The temperature sensor is located near the additional resistor unit.
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THERMAL COMFORT
ADDITIONAL RESISTOR UNIT
The additional resistor unit heats the fluid in order to ensure that the passenger compartment is heated.
The unit is activated when the "GO" position is set and a heating position is requested.
It may be activated for the "preheating/cooling" function.
Composition
The unit comprises:

- an electronic stage,
-
a "PTC" type electric resistor assembly (Positive Temperature Coefficient),
a Gore-tex membrane in order to prevent condensation in the electronic stage.
Actuation
Control
supply:
14 volts (+, and signal).
Power supply:
400 volts.
The unit is actuated and diagnosed by the EVC computer via an LIN network.
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THERMAL COMFORT
To find out more
In order to improve the vehicle range, a request is made to inhibit the operation of the unit for:
- An external temperature or coolant temperature threshold.
- Passenger compartment ventilation in position 0.
- A low traction battery voltage.
- A fault on the electric pump.
MANUAL AIR CONDITIONING

Control panel
Heater unit
UCH
External temperature
Supply (+, -)
EVC
Fluid temperature
CAN
LIN
Prote
ction
400 volt supply

Additional resistor
unit
The UCH manages:

- the buttons and indicator lights on the control panel,
- the transfer of data to the EVC computer and the UPC.
The EVC computer manages the following functions:
- management of additional resistor unit actuation
- management of preheating/cooling,
- management of auxiliary heater activation,
- the transfer of data to the UCH and UPC.
The UPC manages:
- activation of de-icing,
- the transfer of data to the EVC computer and the UCH.
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THERMAL COMFORT
AUTOMATIC AIR CONDITIONING
Heater unit
UCH
Prot
ectio
Air conditioning computer
De-icing
Self-contained heating coolant pump
EVC
Fluid temperature
The climate control system has its own computer.
Two configurations connecting the tank to the heating circuit
This connection limits the volume of fluid to be

heated and enables the temperature to rise
quickly.
The main function of the tank is to display the
fluid level
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This connection ensures that the fluid circulates

correctly throughout the entire circuit.
The tank is used to display the level and the quantity
of hot fluid available.
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THERMAL COMFORT
AUXILIARY HEATER DEVICE
Description
Fuel tank
Heating by auxiliary heater
Identification
Fuel metering pump
Inlet air unit

(air / water
separation)
The "Hydronic II"

auxiliary heater
operates with
diesel fuel or
biodiesel (B30)
Exhaust silencer
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THERMAL COMFORT
Location
Operation
Fuel supply pipe
Fluid outlet
Fluid inlet
Air supply pipe
Auxiliary heater connector
Fuel tank
The fuel tank is specific to vehicles equipped with an auxiliary

heater and comprises:
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A 13 litre tank with integrated foam to avoid fluid lapping

noises,
A switch informing the EVC computer of the minimum fuel level.

The float signal changes status when approximately 3 litres of
fuel remains in the tank.
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SKILLS COURSE
THERMAL COMFORT
COLD LOOP
The cold loop is identical to a combustion engine vehicle.
There are a few special features.
REFRIGERANT FLUID AND LUBRICATION

R134a refrigerant fluid is used.
Lubrication is ensured by the POE (polyolester) type specific oil. It
guarantees the electrical insulation resistance of the compressor with
respect to the rest of the vehicle.
COMPRESSOR
Identification
The electric compressor is a SCROLL type compressor.
It is no longer driven by a belt but by an electric motor integrated into the
compressor.
Location
The compressor is fitted in the same location as on a
combustion engine vehicle. The compressor is secured
to the frame of the motor.
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THERMAL COMFORT
Composition
The compressor is composed of several sub-assemblies:
An electronic stage
The compression
mechanism
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An electric motor
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THERMAL COMFORT
Actuation
Manual air conditioning
Refrigerant pressure
Evaporator temperature
400 volt supply
Rotation speed
EVC
Compressor

Internal temperature
Solar radiation
Customer request (AC)
Air conditioning
computer
400 volt supply
Rotation speed
Compressor
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SPECIAL FEATURES OF THERMAL COMFORT ON KANGOO

Z.E.
GENERAL INFORMATION
The thermal comfort system of the KANGOO Z.E. vehicle is available in the following versions:
Heating by auxiliary
heater
Heating and ventilation

with recirculation
Manual air conditioning
HEATING BY AUXILIARY HEATER

Identification
In order to optimise the battery range, a heatertype device can be activated.
Activation
ACTIVATION
FUEL LEVEL
FUEL TANK
The heater is activated by a button. When the warning light is switched The KANGOO Z.E. is equipped
An indicator light on the button
on, it indicates a low fuel level.
with a flap and a cap.
shows the activation.
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Z.E.
HEATING FUNCTION
Heating is active as soon as the cursor is on the red screen print.
Stopping the heating function:

A new position enables heating to be inhibited via the "Maximum cold" position. In order to limit the impact of
heating on the vehicle range, the additional resistor unit is deactivated when the mixing control is positioned
at "Maximum cold" (blue).
Actuation
In order to ensure the "Maximum cold" function, a microswitch is
positioned at the rear of the control panel.
PREHEATING/COOLING FUNCTION
Preheating/cooling makes it possible to program the passenger
compartment comfort whilst the vehicle is connected to the
electric network and the battery is recharged.
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Z.E.
PREHEATING/COOLING FUNCTION (CONTINUED)
Activation
This function enables the vehicle to be used at a more comfortable temperature and to optimise the battery
range.
Starting
Programming
Deactivation
The vehicle is activated one hour before the time set by the customer.
If the vehicle is not connected or the battery is not charged, preheating/cooling does not occur and the
vehicle is deactivated again.
Programming the time

Starting
Programming
Only preheating/cooling by heating and ventilating the passenger compartment is available.

If the vehicle is equipped with a heater, it cannot be activated for preheating.
Deactivation of preheating/cooling
Starting
Programming
Deactivation
Only preheating/cooling by heating and ventilating the passenger compartment is available.

If the vehicle is equipped with a heater, it cannot be activated for preheating.
In order to ensure the preheating/cooling function, a microswitch is positioned at the rear of the control panel.
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Z.E.
PREHEATING FUNCTION (END)
Deactivation of preheating/cooling (continued)
Preheating/cooling is stopped:
- Approximately 30 minutes after the time programmed by the customer,
- The vehicle is no longer connected to the mains (electric network),
- The customer turns the mixing control away from the "preheating/cooling" position.
LOCATION
Heating unit
Fuel flap
Expansion bottle
Heating by auxiliary
heater
Fuel tank
ACTIVATION CONDITIONS
The auxiliary heater relay is activated if the following conditions are fulfilled:
- The vehicle is in "GO" mode.
- The user has pressed the heater activation button on the dashboard.
- The minimum fuel level is not reached,
- No faults are identified by the electric coolant pump.
- The mixing control is not in the "Maximum cold" position,
- The passenger compartment ventilation is activated.
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Z.E.
MAINTENANCE
It is essential to isolate the vehicle before any

operations are performed on components supplied
with 400 volts.
400 V
Before performing any operations on the heating circuit, it is essential to refer to

the technical documentation to find out if it is necessary to perform lockout on the
vehicle.
COLD LOOP
Actuation
14 volts
Earth
LIN
400 volt supply
Low pressure gas inlet
Earth safety strap

High pressure gas outlet
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SPECIAL FEATURES OF THERMAL COMFORT ON FLUENCE

Z.E.
GENERAL INFORMATION
FLUENCE Z.E. is only available with climate control.
FLUENCE Z.E. is not equipped

with an auxiliary heater device
even as an option.
Climate control.
"ECO" FUNCTION
Identification
The "ECO" button replaces the "SOFT" button which is already

known.
This mode limits the electrical consumption of the air
conditioning (heating and air conditioning) by lowering the
passenger compartment comfort slightly.
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Z.E.
Operation
Each time the "ECO" button is pressed, the system equalises the temperature settings with the driver's
temperature.
When the passenger's setting is modified, the settings are desynchronised again.
"OFF" FUNCTION
The "OFF" function is moved on the "minimum fan" button:

The instrument panel switches off when this button is
pressed even though there is only half a blade lit.
PRECONDITIONING FUNCTION
Preconditioning makes it possible to
program the passenger compartment
comfort whilst the vehicle is connected to the
electric network and the battery is
recharged.
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Z.E.
Activation
The customer has the option of programming 2 schedules (time 1 and time 2) visible on the instrument panel.
Each time the button is pressed, the status is modified according to a 3-status logic:
"OFF" function
Program 1
Program 2
HEATING CIRCUIT
Installation
Heating unit
Expansion bottle
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Self-contained heating
coolant pump
91
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Z.E.
The climate control system has its own computer.
UCH
Heater
unit
Prote
Computer
Heating and
til ti
De-icing
Self-contained heating coolant

pump
EVC
Fluid temperature
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Z.E.
MAINTENANCE
It is essential to isolate the vehicle before

any operations are performed on
components supplied with 400 volts.
Before performing any operations on the heating
circuit, it is essential to refer to the technical
documentation to find out if it is necessary to
perform lockout on the vehicle.
COLD LOOP
The cold loop is identical to a combustion engine vehicle.
The cold loop has a thermostatic expansion valve and

dehydration reservoir.
The cold loop of FLUENCE Z.E. uses some of the

components of the cold loop system on the FLUENCE
combustion engine except for the compressor and some
of the pipes.
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Z.E.
"INTERNAL HEAT EXCHANGER" ASSEMBLY
In order to optimise the output of the cold
loop, an "IHX" assembly is present. This
system inside the heat exchanger
reduces the amount of energy requested
by the compressor.
ACTUATION

Solar radiation
Customer request (AC)
EVC
Compressor
Rotation speed
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Z.E.
Heater unit
De-icing
Humidity
Solar radiation

UCH
Heating coolant
pump
EVC
Protection and
switching unit
Compressor
Fluid temperature
The UCH computer manages:
- The "de-icing" function,
- The transfer of data to the EVC and the air conditioning computer.
The UPC computer manages:
- Actuation of the cooling fan assembly.
- The cold loop,
- Compressor actuation,
- The hot loop,
- Actuation of the additional resistor unit,
- The transfer of data to the UPC, UCH and the air conditioning computer.
The air conditioning computer manages:
- The user interface,
- The automatic modes,
- The "ECO" function,
- The transfer of data to the UCH and EVC.
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Z.E.
NOTES
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BRAKING
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BRAKING
SPECIAL COMPONENTS
Computer
VPM
Vacuum pump
Dual vacuum sensor
VPM COMPUTER
Function
The VPM (Vacuum Pump Module) computer actuates the vacuum pump
according to the vacuum value sent by the dual vacuum sensor.
If a fault is detected on one of the system components (brake pedal
information, pump, sensor, etc.), the VPM computer sends the information
to the EVC computer in order to display a warning message on the
instrument panel.
The VPM computer makes the operating time of the vacuum pump
available to the EVC computer.
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BRAKING
DOUBLE VACUUM SENSOR
Function
The dual vacuum sensor enables the computer to know the vacuum present in
the braking assistance circuit.
For safety reasons, the vacuum sensor has two stages.
As on combustion engine vehicles, a non-return valve is used to maintain the
vacuum.
VACUUM PUMP
Function
The role of the electric vacuum pump is to generate the vacuum for
braking assistance purposes.
It is supplied with 14 volts.
The vacuum is achieved by a rotary vane pump.
ACTUATION
Motor Fuse and Relay Box (BFRM)
Vacuum pump control
EVC
LIN
Protection
and
switching
unit (UPC)
+ After ignition
Sensor signal
Supply
The VPM computer is connected to the EVC computer by an LIN connection. Fault finding is performed on the
VPM computer using the CLIP tool, the EVC computer and the vehicle multiplex connection.
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BRAKING
OPERATION OF THE VACUUM PUMP
Operating strategies
Braking
When the brake pedal is depressed, the vacuum in the brake servo is consumed.
Off
On
Safety
On
When the vacuum measured in the brake servo reaches the "On pressure" value, the pump is triggered in
order to maintain braking assistance.
Off
On
Safety
Off
As soon as the vacuum measured reaches "Off pressure", the pump stops.
Off
On
Safety
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BRAKING
Safety
In the event of a leak, the vacuum created by the pump cannot be maintained and reaches the "safety
pressure" threshold value. The pump operates and a message is displayed on the instrument panel.
Off
On
Safety
NOTES
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BRAKING
NOTES
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MAINTENANCE
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MAINTENANCE
SPECIAL FEATURES OF KANGOO Z.E.
FAULT FINDING
BORNEO 3
The diagnostic socket is located in the central

console.
Fault finding is performed using the CLIP tool on
the Borno 3 interface.
IDENTIFICATION
The identification points of KANGOO

Z.E. are the same as the combustion
engine vehicle.
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MAINTENANCE
TOWING AND LIFTING THE KANGOO Z.E.
Lifting points identical to combustion

engine vehicles.
Do not install any vehicle jacking components

- Under the orange high voltage cable routings,
- Under the traction battery.
In the event of a fault, KANGOO Z.E. can be towed according to the different configurations.
Caster wheels
Caster wheels
IN THE EVENT OF THE VEHICLE BEING INVOLVED IN AN ACCIDENT, THE VEHICLE MUST
BE TRANSPORTED ON A PLATFORM.
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MAINTENANCE
SPECIAL FEATURES OF FLUENCE Z.E.
FAULT FINDING
BORNEO 3
The diagnostic socket is located in the central

console.
Fault finding is performed using the CLIP tool on
the Borno 3 interface.
IDENTIFICATION
The identification points of

FLUENCE Z.E. are the same
as the combustion engine
vehicle.
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MAINTENANCE
TOWING AND LIFTING FLUENCE Z.E.
Lifting points identical to combustion

engine vehicles.
Do not install any vehicle jacking components:
- Under the orange high voltage cable routings,
- Under the traction battery.
In the event of a fault, FLUENCE Z.E. can be towed according to the different configurations.
Caster wheels
Caster wheels
IN THE EVENT OF THE VEHICLE BEING INVOLVED IN AN ACCIDENT, THE VEHICLE MUST
BE TRANSPORTED ON A PLATFORM.
TRAINEE BOOKLET
RENAULT Z.E.
107
RENAULT Reproduction or translation, in part or in full, is prohibited without the authorisation of Renault 2011

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SKILLS COURSE

MOTOR AND TRANSMISSION ASSEMBLY

ELECTRIC MOTOR AND TRANSMISSION ASSEMBLY COOLING

ELECTRIC VEHICLE TRAINING

A 400 volt network

The electric vehicle has a 14 volt electric network for:

Motor fuse and

Traction battery charger

Converter assembly (PEB)

Electric vehicle central

Traction battery computer

Electric vehicles have a passenger compartment fuse and relay box

MOTOR FUSE AND RELAY BOX / UPC

Protection and switching unit (UPC)

THE EVC COMPUTER

Management of the traction and cruise control/speed limiter

Management of the charge

Management of the various instrument panel messages

Mileage counter with reset in kWh

Overall instant vehicle consumption in kW

Average consumption in kWh/100

1st insulation fault

2nd insulation fault

2nd insulation fault

Earth straps are present on all components supplied with

THE EVC COMPUTER MANAGES THE FOLLOWING FUNCTIONS:

Electric coolant pump

400 volt network

400 volt network

In an electrical vehicle, the

Converter assembly connector

The converter assembly is paired to the UCH

The UCH controls activation and deactivation

Lead without EVSE

400 volt battery

Management of the charge

3 wire lead + "control pilot" wire

The lead has 3 wires:

The "control pilot" wire

The "control pilot" wire is a control signal which informs

The EVSE (Electric Vehicle Supply Equipment) unit is

- an electronic stage which enables the switch to be

MAXIMUM CURRENT RANGE: 230

IT IS ESSENTIAL TO MAKE THE VEHICLE SAFE BEFORE DISCONNECTING

Connector correctly locked:

Connector incorrectly locked:

Repairing wiring and power connections is strictly

Power relay unit

Traction battery computer

Insulators: they protect

Weight: approximately 250 kg

Bar plugs are interconnecting plates for the modules.

The safety circuit has:

When the vehicle is switched on, relay A is actuated first.

Then relay N is closed.

The temperature of the stacks and modules is monitored using sensors.

FUNCTION OF THE LBC COMPUTER

When charging, the module voltage

Secured to the bodywork by bolts

Power relay unit

Earth safety strap

Connecting and locking the battery

Quick drop locks

The "Quick drop" locks ensure that the battery is secure.