[WIP] BMW E6 - 2002 Touring

[nkiernan]

Note in the menu capital letters make a difference, think it's 'p' vs 'P' for example. I saw something similar then realised caps lock.

[mane2]

btw, sbox sees 60V too.

Code: Select all

***************************************************************************************************
Battery Current: 15.00mA
Battery Voltage: 89.90V
Output Voltage: 60.10V
CAN 0x100 control byte: 86
***************************************************************************************************

and when hitting capital A (close all contactors) it shows 90V

Code: Select all

***************************************************************************************************
Battery Current: 18.00mA
Battery Voltage: 89.90V
Output Voltage: 90.10V
CAN 0x100 control byte: AA
***************************************************************************************************

[tom91]

Code: Select all

***************************************************************************************************
Battery Current: 13.00mA
Battery Voltage: 89.90V
Output Voltage: 0.23V
CAN 0x100 control byte: 0
***************************************************************************************************

When you have all the contactors shut what does it show there? If you are loosing 30V somewhere there is a high resistance and it would suggest the contactors are not great condition or some other resistance.

Will have a quick look at the code.

[tom91]

btw, sbox sees 60V too.

Code: Select all

***************************************************************************************************
Battery Current: 15.00mA
Battery Voltage: 89.90V
Output Voltage: 60.10V
CAN 0x100 control byte: 86
***************************************************************************************************

and when hitting capital A (close all contactors) it shows 90V

Code: Select all

***************************************************************************************************
Battery Current: 18.00mA
Battery Voltage: 89.90V
Output Voltage: 90.10V
CAN 0x100 control byte: AA
***************************************************************************************************

Precharge... resistor doing something or some other loop through a measurement circuit

Mind measuring the resistances when commanding the different contactors.

[tom91]

Btw code from zombie is this:

Code: Select all

switch (opmode)
   {
      case 0:
        CCByte=0x00;//all contactors off
         break;
      case 2://Precharge
        CCByte=0xA6;//Prech and Neg contactors activated
         break;

      case 1://Run
        CCByte=0xAA;//All contactors activated
         break;

      case 4://Charge
        CCByte=0xAA;//All contactors activated
         break;

      case 3://Precharge fail
        CCByte=0x00;//all contactors off
         break;

    }

you have a reported 0x86 which is not here

Yup so 0x86 is just precharge, which will cause leakage through HV measurement circuits, NOT a state you ever want to be in. Precharge never is the only one active.

[mane2]

Yeah, I guess it leaks, but only when positive or precharge relay is enabled.

Test with 120V battery voltage:

Code: Select all

negative contactor active (0x62) = 0V 
positive contactor active (0x0A) = 80V 
precharge active          (0x86) = 80V 
positive and precharge    (0x8A) = 80V 
negative and precharge    (0xA6) = 120V
all contactors activated  (0xAA) = 120V

But yeah, It seems to be okay if only using those commands that Zombie has. So on precharge do negative + precharge (0xA6) and once voltage is up, do all (0xAA)

I guess this is the case with others using sbox too? Just got me wondering if something is broken here, I guess not.

[tom91]

Nothing is broken, you can break it if you do not use it correctly.

The box is designed to function as per Zombie code, doing anything else can break it.

[mane2]

Come on Tom. That applies to everything, even toothbrush or shovel.

How are you guys doing HV isolation monitoring? On my other car Orion BMS handles that, but this car will use SimpBMS and it does not have that. This seems to be the only cheap option https://www.ebay.at/itm/196329086628 but shipping to Europe is like 45 euros + customs + vat. Also it does not have the connectors. Any other solutions out there, preferably available in Europe..? I guess most of ev-conversion cars just do not have that?

[mane2]

Progress update. New trunk floor with outlander charger and 12V battery in place. Motor mounts done and cooling. Radiator, pump and hoses done. Batterybox almost done and painted, just missing data cable connector. Remote reservoir for iBooster. Brake balance/proportioning valve installed for rear drums as well as new brake lines. Testing out e-ink display for showing state of charge, range and other things. Bought VW Golf mk3 GTI seats to replace those big sofas. 3d-printed plastic rollers to rear trunk lid shock arms. Epoxy + raptor paint for new metal parts. Front struts modified to have level adjustability. New coils to front.

Next week:
- install small E21 front hubs (to allow vented rotors)
- install E21 323i vented rotors
- install Volvo 240 calipers and pads (only ones that fits factory BMW 2002 strut mount with those vented rotors)
- finish brake lines and bleed the system

Week after that:
- Take the car to painter to install 2002 Turbo fender flares.

Originally I was thinking of not having those turbo fender flares, but as front wheel well is so shallow, wheel would hit the fender lip with these rims or the car would have to sit very high - which just looks bad. Rims would have to be 6" with 175mm ET30 tire to go inside the wheel well. Those kind of 4x100 rims are very hard/impossible to find with nice styling. So need to do the turbo-mod.

[mane2]

Lots of progress during past month.

Desinged a frame for esp32 display (lvgl, can, esp, touch display)

Original plan to have Golf GTI seats did not happen, as seller couldn't find the seats. So plan B, BMW 2-series (G42) alcantara sport seats. This simple seat replacement accumulated way bigger project, as original seats sit high on top of transmission tunnel but new seats need to go to bottom. So first the tunnel was cut a bit, then bit more.. until we realized that they don't sit straight in front of steering wheel.. So need to cut more.. and eventually, whole floor was completely removed and made a new one to make the seats align and sit low enough properly

Rear drums also gave a headache, as they we party stuck and adjustment screw was so round and stuck that it was not revivable. New turbo drum brakes from Walloth & Nesch was around 1000 euros.. So started looking for alternatives. 2002 forums blog post suggested using VW Golf MK1 front rotors, MKIV calipers, Golf carrier and custom brackets. So went with that.

As floor was removed and rear brakes upgraded, some new handbrake wiring was required.

As car sit lower, rear camber was way off. So new plates were done to allow camber and toe adjustment.

Next up is revamping the rear shocks, plan is to replace separate coil and damper with coilovers.

[zippy500]

Like your nice clean professional conversion.

I am converting a E10 2002 with leaf motor, mine is more "Heath Robinson" lol

[jrbe]

Nice work!

Just watch out for welding the bolts with the eccentrics, it changes the bolt hardeneing / strength. You might be able to find some that have the eccentric as part of it or the many keyed styles OEM's use like the D shape, pin, etc.

[mane2]

Like your nice clean professional conversion.

I am converting a E10 2002 with leaf motor, mine is more "Heath Robinson" lol

Thanks! This project was supposed to be much more like that in the beginning, but as my friend happened to have time to help with metal and mechanical work, things got out of hand and become full professional. Once the car gets painted and I get it back to my garage the professionalism goes out from the door

[mane2]

I am converting a E10 2002 with leaf motor, mine is more "Heath Robinson" lol

Do you have a build thread/instagram etc? Would be interesting to follow that!

[mane2]

Nice work!

Just watch out for welding the bolts with the eccentrics, it changes the bolt hardeneing / strength. You might be able to find some that have the eccentric as part of it or the many keyed styles OEM's use like the D shape, pin, etc.

Thanks. I think the idea was to find the correct position with that and weld it fixed.

[mane2]

Some progress on my custom bms solution for bmw hybrid pack. Got the balancing, reading the voltages, etc. Most major thing being able to dynamically add and modify settings in console with added lvgl and display support having console on screen and modifying all setting without terminal access. It’s using Teensy 4.1 and skpang dual can display with touch solution. I tried to do custom board for this but it seems surprisingly difficult to match footprints for components that match jlcpcb or pcbway components. Need to take a round two for that later.