openinverter forum

BMW Battery Management Electronics SME ???

this will cure your insomnia

so I went out and bought some new battery cables, I bought two of the main negative lead cables, as they are the longest in the pack

bmwpartswholesale.com
Part Number: 61-27-8-621-016
Price: $58

the ends are keyed so they go in a certain way

I decided to pop one open to see how it was built, since I could feel that there were really two wires side by side in that orange mesh housing

I wish I could ask the German engineers if there is another reason for the side by sideness other than the flatness

having acquired the new expensive battery cables, I thought the sensible thing to do was to cut one up [ immediately ]

Ah Yeah! The Crimpulator 3000 is here! not bad for $32 bones on AMAZON

and so we got to work on my test battery cables, for this I needed a bunch of yellow tools

I decided to add a little color coding to the two solid orange main leads, first some black heat shrink tubing went on both ends of the negative cable

and here is what the six cell modules look like all connected just the way they were inside the pack

Note the short orange wire on the far right, that's was the original main Positive lead that came off of Cell Module # 6, I decided to replace it with the same orange wire that runs from Cell Module # 1 on the left (that is what the original looked like) so now both leads match

One lead was originally shorter than the other. BMW did that because the leads ran to the Safety Box which was located on the right side of the battery pack closer to Cell Module # 6

think positive

so I decided to rock the Anderson SB120 connector because it uses powerpoles that will fit these battery cables, two into one type of thing

i heart this battery pack


[what? .... too soon!]

this used to be a "Safety Box" aka the BMW 530e OEM Pre Charge circuit

so although I have a dedicated thread called I bought a Tesla Model S Gen 2 Charger - Now What? I hope you don't mind me oversharing some info on the 34 pounder here as well

this video attempts to explain how and why I chose it

then it was time to take a peak inside

I labeled the AC input and the DC output

in order to get this charger to work minus the actual OEM Tesla vehicle, I had to replace the logic board with one of Damien Maguire's


old board is out (it is much denser in component population than the new one I will be replacing it with)

comparison of the OEM Tesla Model S Gen 2 charger PCB with the new Open Source one

the new open source board comes with the red card already programmed with Dipl. Ing. Johannes Hübner's code allowing it to manage the charger using a Craigslist like GUI (simple yet powerful)

the new charger circuit board does NOT come with neither of the two header connectors, and do to the electronic parts shortage at the time of this build I had to harvest one of the connectors off of the OEM board (using only the finest precision tools)

Fun Level: -2

don't tell me it can't be done ha ha


needless to say the Cuss Jar is FULL !

using lasers and robots to clean them feets

new open source Damien Maguire logic board for the Tesla Model S Gen 2 onboard charger built and installed

next I set out to build the low voltage (12v) wire harness, this would power up the logic board inside the charger (but not the actual three power module bricks) that's ok this would allow me to "talk" to the card

and with a little luck that red wifi card would broadcast it's network and using a laptop and a browser I was able to connect to it's Craigslist like (meaning simple yet super powerful, I love it) Johannes Heubner user interface