E46 Touring with GS450H Gearbox Motor

[Domt177]

I've a remark on the Renault Charger System if you want to use it in a conversion, the Chameleon Charger uses the motor as part of the charging system, it is not a seperate unit.
If you look at the following site you find some comments to it.
https://www.eqpassion.de/en-gb/Efficien ... d_feedback

Does the Zoe use its motor as for AC as well as DC Charging?

[Kevin Sharpe]

Does the Zoe use its motor as for AC as well as DC Charging?

The early ZOE's (pre CCS) do not support DC charging.

[Martin1775]

The motor is used for the AC charging as replacement for the transformer or inductor in the charger.
For Chademo or CCS, the charging technic is not installed in the vehicle, it is in the charging station.

[Domt177]

The motor is used for the AC charging as replacement for the transformer or inductor in the charger.
For Chademo or CCS, the charging technic is not installed in the vehicle, it is in the charging station.

Interesting, the Zoe uses AC Quick charging and doesn't support DC, Suppose I won't be using that charger then.
thanks

[AlexD]

Interesting project, im gearing up to do the same in an E61 so will be watching this closely.

[Domt177]

Interesting project, im gearing up to do the same in an E61 so will be watching this closely.

Brilliant, thinking of making a YouTube series of it once I start

[Domt177]

Anyone know is there is a weight limit I have to come under for the final product, as I seem to recall there being a weight limit when modifying a vehicle in the UK, i.e. you can't go a certain weight over the original car when the modified car gets re-tested by the surveyor.

Will most likely get a 330D to start with which is the heaviest version that isn't 4wd

[AlexD]

Isn't it done on your license as opposed to the vehicle?

In which case on a normal Cat B License it would be upto 3500kg

[Domt177]

Think I’ll find a whole Tesla pack and use some of that, as I’ll be EV conversing 2 classic minis soon also, makes more financial sense to get a whole Tesla pack and split it between the 3 cars

[AlexD]

How much kWh are you going to use in the E46? How much mileage do you expect to get from it. I'm hunting like crazy for some nicely priced packs.

[Domt177]

How much kWh are you going to use in the E46? How much mileage do you expect to get from it. I'm hunting like crazy for some nicely priced packs.

Hoping to fit 8 of the 16 modules into the bimmer (other 8 will be split into each mini) what would give me 42.4kWh nominal so about 39kWh net.

If I can fit a 9th module in that would be ideal as I’m hoping to get 150mi out of it, that would bring me up to 44kWh net which sounds a bit more realistic for my range needs.

[Domt177]

So if I’m planning on using 9 Tesla modules, each with a voltage of 22.8v, that would give me a pack voltage of 205.2, but the Lexus inverter needs 280v as stated in the openinverter wiki page (unless I’ve read that wrong). Supposing that means I need to use some sort of voltage booster? Any other ideas?

[Domt177]

Is there the possibility of doubling the voltage of the Tesla modules since they use a 6S cell layout.

[slow67]

So if I’m planning on using 9 Tesla modules, each with a voltage of 22.8v, that would give me a pack voltage of 205.2, but the Lexus inverter needs 280v as stated in the openinverter wiki page (unless I’ve read that wrong). Supposing that means I need to use some sort of voltage booster? Any other ideas?

Ive ran my Lexus inverter on 12V.

[Domt177]

Ah ok so the worst outcome of me running it on 200v is reduced power output?

[slow67]

Ah ok so the worst outcome of me running it on 200v is reduced power output?

Reduced maximum rpm/speed.

[Isaac96]

Ah ok so the worst outcome of me running it on 200v is reduced power output?

Reduced maximum rpm/speed.

Mostly (we do have field weakening, remember the 650v legends?). 200V is about half of what you want though -- it'll be less efficient as well as less powerful.

[Domt177]

Ah ok so the worst outcome of me running it on 200v is reduced power output?

Reduced maximum rpm/speed.

Mostly (we do have field weakening, remember the 650v legends?). 200V is about half of what you want though -- it'll be less efficient as well as less powerful.

Understandable but I don’t think there’s another way around it, I could use i3 batteries which are 5.3 kWh per module but double the voltage, but can’t find any in my budget considering I’ll be buying a whole Tesla pack as i’m doing another EV conversion with the rest.

[Domt177]

The one last thing I’m unsure about is DC Fast Charging with a 230v nominal battery, this seems a little low to me for DC fast charging or am I overthinking?

[Isaac96]

The one last thing I’m unsure about is DC Fast Charging with a 230v nominal battery, this seems a little low to me for DC fast charging or am I overthinking?

230V should work. The Zero motorcycles that had issues with low voltage had 120V packs -- the 50-125V range is the 'optional' part that was not implemented by all chargers.

[Domt177]

At 230V, because all the chargers are rated at 120A Max, all I’ll get is 25 odd kW (not particularly good)

Can I just use a buck converter from 400V @ 125A down to 200ish V @ 250ish A

Would need to figure out some way to control that into the battery

[Domt177]

Almost finished the planning stage, just stuck on batteries, would love some advise, I have about £6k for a battery setup and would like something >45kWh net, ideally with liquid cooling for DC quick charging.

1. 10x Tesla 5.3kWh Modules
Pros: Readily available within my budget, lightweight, easy to work with, liquid cooling already implemented, SIMP BMS
Cons: 230V pack voltage means limited power output and no / limited DC-QC charging (25kW limit due to 125A limit)

2. 10x BMW i3 120ah (5.3kWh) modules
Pros: 460V pack voltage so good for power+ DC-QC, liquid cooling, Lightweight, SIMP BMS
Cons: Can’t find them anywhere for a decent price (happy to wait though as not in a rush)

3. 17x Mercedes B250E Tesla modules
Pros: plenty of volts, liquid cooling, lightweight etc.
Cons: nowhere to be seen, especially in 17 module quantity, (also not SIMP BMS compatable??)

Open to other battery ideas if I’m missing out on something.

Finally, where do I look for a GS450H Parts car, I’ve been looking on Copart or is it just a case of looking on gumtree/eBay/Facebook every once in a while until I find a nicely priced one?

Thanks

[mdrobnak]

Watch out re: i3 - Tom has said there's a 6 or 8 module limit due to addressing of the modules - that still gets you 42.4 kWh / 368V at 8 modules, which is good. Note that chargers get more expensive over 400V... I will probably head down the i3 route when I want to expand my battery capability.

-Matt