Info on BMW hybrid battery packs?

[sprocketman]

I have added some photos of inside the contactor box.

BMW contactor box internal

BMW contactor box internal 2

BMW contactor box internal 3

BMW contactor box internal fuse

BMW contactor box internal contactor

BMW contactor box internal contactor 2

BMW contactor box internal contactor 3

[sprocketman]

I am using the components of the BMW contact box for my project.
I had to cut down to fit in a smaller gap inside my battery box.

Battery box made from a cut down enclosure

Basic components

Cut down contactor box

Resistor and precharge contanctor rotated 90 deg

Also I cut off the plug in connections so that I can use the BMW connectors to connect to the batteries. I also drilled and re bent the copper bus bars to fit.

Just fits in the batery box

Laminate flooring as an insulator

I am going to fit 12 batteries in this box, two sets of 6 in parallel. One above the other with 40mm spacers in-between the batteries.

Does anybody have any suggestions how to do the connections? I was considering using two sets of contactors for each 6 batteries so that if one fails I should still get home.

[black-cat]

Anyone know a cheap source of the interconnect cables? I'm doing two 3 module packs so need some more of the longer cables.

[sprocketman]

If you have 3 full packs there should be enough connectors for each cell.
I would consider lengthening the cables by adding a bit in the middle.

I haven't been able to find the connectors.

[black-cat]

Trying to keep the joints to a minimum

Finding unshielded 16mm HV cable seems to be a struggle too.

[sprocketman]

I am using 4 core SWA 16mm cable. It's a bit stiff but should take the current. Why do you want unsheilded cable?

[storm4710]

with the slave and master system would it be possible to build a high voltage battery pack and keep the bms system and contactor ?

pre-charge capacitor would have to be changed to some higher voltage

[sprocketman]

I have used that set up with 10 units in series for a short period without any problems. However it is over the voltage rating of the components so probably not good for a permanent installation.

[storm4710]

I have used that set up with 10 units in series for a short period without any problems. However it is over the voltage rating of the components so probably not good for a permanent installation.

the idea was 8 or 9 in series

[johnspark]

Anyone know a cheap source of the interconnect cables? I'm doing two 3 module packs so need some more of the longer cables.

Is there a Toyota wrecker nearby? If yes, try to extract the DC cables that used to go to inverter and to the battery. You will need access to the underneath of the wreck. I suggest this because these cables are shielded and higher temperature rating and 16mm2 or thicker. You should be able to get about 2m length or so.

[sprocketman]

Renumbering CSCs now implemented. So any 6 can be be used and renumbered as needed.

Update is on github

Hi Tom,

I managed to get all 6 modules reading voltages previously but I have done somthing now and I an unable to read any info from the modules.
If I select output check in the debug menu all 6 modules apear but they are reading 0v apart from min volts which reads 5v?

I am hoping i have done somthing simple but I am scratching my head at the moment?

[tom91]

Renumbering CSCs now implemented. So any 6 can be be used and renumbered as needed.

Update is on github

Hi Tom,

I managed to get all 6 modules reading voltages previously but I have done somthing now and I an unable to read any info from the modules.
If I select output check in the debug menu all 6 modules apear but they are reading 0v apart from min volts which reads 5v?

I am hoping i have done somthing simple but I am scratching my head at the moment?

Reset to factory settings and see if that fixes it, or worst case load firmware again.

[sprocketman]

Thanks Tom,

I have tried all these methods.

Regards

Andrew

[tom91]

Check all your connections. check if there is any canbus activity. check the canbus termination resistor.

[sprocketman]

Check all your connections. check if there is any canbus activity. check the canbus termination resistor.

Thanks Tom,

The last time I disconnected it when it was working, one wire contacted the battery with a spark so I may have damaged something. However the teensy still works and I can get can from the modules. I just hope I haven’t damaged the slave units?
I connected a can logger and the teensy in parallel and the code stops on the logger when the teensy is connected.


code from the logger on the modules

Get data from ID: 100
0 0 0 10 0 0 0 7A
Get data from ID: 101
0 0 0 10 0 0 0 1F
Get data from ID: 101
0 0 0 10 0 0 70 46
Get data from ID: 1C5
22 22 92 22 22 22 42 22
Get data from ID: 202
3E 3E 40 50 41 0 0 0
Get data from ID: 205
3E 3E 40 45 41 0 0 0
Get data from ID: 102
0 0 0 10 0 0 0 B0
Get data from ID: 100
0 0 0 10 0 0 90 91
Get data from ID: 101
0 0 0 10 0 0 80 39
Get data from ID: 103
0 0 0 10 0 0 10 18
Get data from ID: 105
0 0 0 10 0 0 50 48
Get data from ID: 104
0 0 0 10 0 0 10 3E
Get data from ID: 100
0 0 0 10 0 0 A0 DB
Get data from ID: 101
0 0 0 10 0 0 90 F4
Get data from ID: 104
0 0 0 10 0 0 20 74
Get data from ID: 105
0 0 0 10 0 0 60 2
Get data from ID: 205
3E 3E 40 45 41 0 0 0
Get data from ID: 103
0 0 0 10 0 0 20 52

[tom91]

The teesny does not report any incoming canbus? Try sorting that out first, possibly blown the can transceiver or section of the teensy.

Good thing is it looks like slaves are sending canbus.

[sprocketman]

Hi,

I have changed the can reciever and that made no differance. So i have ordered a new Teensy.
Do the can bus messages look ok. looks like a lot of zeros to me?

thanks again

Andrew

[tom91]

How many modules you have connected? Also what else is connected?

I see 6 modules reporting they are ok. IDs 100 - 105

[sprocketman]

How many modules you have connected? Also what else is connected?

I see 6 modules reporting they are ok. IDs 100 - 105

Everything is working again now I have used the new Teensy.

I just had 6 modules connected
Thankyou for your guidence Tom. I have been stuck on this for a few weeks.

Andrew

[sprocketman]

Renumbering CSCs now implemented. So any 6 can be be used and renumbered as needed.

Update is on github

Hi Tom,

Is it possible to read more than 6 modules? I connected 11 (I need to make new cable for 12). It reads 11 modules but only displays voltages for 6?

Thanks again

Andrew

[tom91]

No this is not. Maximum number of modules is set by BMW, I believe its 6 or 8.

You can use the reset IDs in the debug menu to have the SimpBMS software run automatic numbering. If they are of range for the BMW slaves they will stop taking the new ids.

[sprocketman]

Thanks Tom I understand now.

[storm4710]

Newtis has been closed by bmw so all newtis links at the first page is now dead

[arturk]

Newtis has been closed by bmw so all newtis links at the first page is now dead

This is sucks big time, newtis was great resource.

[Jack Bauer]

I did wonder how long that site would stay up. Shame. Leave it with me.

Edit : For those looking for a source of BMW wiring and tech info the following Android programs are a good resource :
https://play.google.com/store/apps/deta ... l=en&gl=US
https://play.google.com/store/apps/deta ... l=en&gl=US