This is still really slow going but at least it's still moving forward
I've machined up a block of nylon to both seal up the hole where the hv enters the inverter and isolate the hv inputs
had some issues with the isa shunt managed to get a 300A one cheap but it wasn't a standard one it was a IVT-300-U3-TOI.CAN 2-12 (happy days) since I had no intention of drawing more current than this, followed Damiens procedure for initialising it with the Zombie and absolutly no change still churning out rubbish tried lots of things to get it working with no joy so I bit the bullet and bought a new 1000 Amp version assuming it was incompatible and the new one did exactly the same which was too much of a coincidence after lots of playing around I managed to get both of them initialised by powering them up before the Zombieverter instead of at the same time never mind all working now
Re: [WIP] BMW Z3
Posted: Sun Oct 29, 2023 8:13 pm
by andybpowell
I seem to have spent this week going around in circles, I thought the layout all planned but for various reasons it didn't work out so had to rebuild the transmission mount to accomodate the dc to dc/charger and inverter and also relocate the transmission oil cooler but it's all done now
the mount has gone from this
to this
Maybe I can actually get on now
Re: [WIP] BMW Z3
Posted: Sun Oct 29, 2023 9:37 pm
by Alibro
Sometimes you feel like an auld dog going round in circles.
Re: [WIP] BMW Z3
Posted: Sun Oct 29, 2023 11:14 pm
by andybpowell
I am an auld dog
Re: [WIP] BMW Z3
Posted: Sun Nov 05, 2023 8:45 pm
by andybpowell
Still slow going but at least it's moving forward my old battery pack is sold and the new 24kwh X5 pack should arrive monday though I seem to be building up a large collection of BMW battery cables as I've 2 complete sets now and the pack I've bought is complete I'll have to get around to selling them at some point.
The 1 series gear lever is pretty much sorted and I've written the code for it and I've got a good idea how I'm going to fix it in the car
the blanking plate for the original HV input is all fitted
As is the new HV input this is it prior to some silicone sealant and the cover
and here it is fitted above the outlander charger/dc-dc, I've also done most of the plumbing and fitted the two coolant pumps I'm considering redoing the coolant hoses with some custom made silicone or metal ones, not sure yet
Re: [WIP] BMW Z3
Posted: Mon Nov 06, 2023 8:42 pm
by andybpowell
Got an early prezzy from santa today
I've removed the top half of the housing and split the pack, I've done this mostly so I can actually move it as it weighs a ton
These are all of the fixings that came out it took an hour
Now it's a bit lighter I can move it to get to the wiring I'll reconnect all of the wiring and get some can logs tomorrow
Re: [WIP] BMW Z3
Posted: Thu Nov 09, 2023 10:27 am
by andybpowell
The X5 pack is all stripped down it almost seems wrong to be doing it because it's so well made in comparison I feel like a caveman tying sticks together, anyway all of the loom has been unwrapped as it needs to be modified as BMW split it where it crosses from the right to left hand side but they have the first and last 3 modules on the right and the middle 6 on the left but it's a relativly minor mod.
This is the Can log if anyone wants it, thanks to Tom De Bree who has already had a look for me and say's it's pretty much the same as the BMW Phev requiring only minor changes to Simp Bms for the number of modules
Wondering what the outer LxWxH including BMS board/connectors are for these modules, are they the same as the BMW modules already noted in the wiki (either i3 or PHEV)?
nkiernan wrote: ↑Thu Nov 09, 2023 1:32 pm
Wondering what the outer LxWxH including BMS board/connectors are for these modules, are they the same as the BMW modules already noted in the wiki (either i3 or PHEV)?
same size as the 16s phev modules the bms slaves are very slightly smaller
Re: [WIP] BMW Z3
Posted: Thu Nov 09, 2023 2:26 pm
by snelly
Looks like the battery pack only just fitted in your workshop must of been fun getting it in there
Re: [WIP] BMW Z3
Posted: Thu Nov 09, 2023 2:31 pm
by andybpowell
snelly wrote: ↑Thu Nov 09, 2023 2:26 pm Looks like the battery pack only just fitted in your workshop must of been fun getting it in there
I had to split the pack just to be able to move it it weighs about 200KG and it was jammed in tight
Re: [WIP] BMW Z3
Posted: Thu Nov 09, 2023 3:01 pm
by Aragorn
andybpowell wrote: ↑Thu Nov 09, 2023 2:12 pm
same size as the 16s phev modules the bms slaves are very slightly smaller
I guess its the same cells just reconfigured as 8s2p?
Re: [WIP] BMW Z3
Posted: Thu Nov 09, 2023 8:05 pm
by andybpowell
I've started rebuilding the front pack and as much as the 16s bms slave to 2x8s battery adapter boards designed by Artur worked perfectly well this is much neater
Other than getting 2 extra modules and the original bms slaves this is the other reason I bought this pack
it's just over a year old
Re: [WIP] BMW Z3
Posted: Thu Nov 16, 2023 8:19 pm
by andybpowell
The front battery pack is nearly ready to go back in I'm just waiting for some resistors for the contactor economiser, the BMW X5 12 X 8S BMS is all working Thanks again Tom and the rear pack is all in and ready to go just need to run a couple of cables to the back
Now that the battery HV cables are all sorted I'm going to have a lot of spares left over probably 10 or more various lengths, the X5 S-box and 12 BMW bms slaves I'll get these advertised at some point.
Re: [WIP] BMW Z3
Posted: Fri Nov 17, 2023 10:45 pm
by Jacobsmess
I might be interested in the SBox
Re: [WIP] BMW Z3
Posted: Sun Nov 19, 2023 6:15 pm
by andybpowell
Since I'm going over to a zombieverter from my own controller now that I'm swapping the LEAF motor for the GS300h I was going to just put a parallel capacitor and resistor in series with the contactor as an economiser circuit but having tried it I wasn't happy with the heat of the resistor or the energy saving it worked fine but since I'm just playing I thought I try something else, I have been using Buck converters in small circuits for years as they are cheap as chips and very energy efficient so I thought why not use one to output 12v at switch on then reduce to a holding voltage for the contactor so I did; This is the circuit diag for the one I'm using it's a variable voltage version and the output voltage is set using a variable resistor r2 in the diagram
if you set your hold voltage for your contactor using the standard circuit using the variable resistor(R2) then put a suitable sized resistor in parallel with R1 until the output is 12V then add an electrolytic capacitor in series with this resistor when you apply power the output voltage will peak at 12 then reduce down to the hold voltage that you set the time taken determined by R1,R2 and the new resistor and capacitor I'm still tweaking the values of the resistors and capacitor but it works really well and it's cheap the last batch of these buck converters I bought cost about £1.60 each.
This circuit is currently using just over 2 Watts per contactor my previous circuit using a parallel capacitor and resistor in series with the contactor was using around 7 Watts and un-economised about 28 Watts I still need to adjust the resistor and capacitor values but so far it's not a bad afternoons tinkering
Re: [WIP] BMW Z3
Posted: Mon Nov 20, 2023 7:22 am
by johu
Awesome, could rip it off and sell
Re: [WIP] BMW Z3
Posted: Mon Nov 20, 2023 7:59 am
by andybpowell
johu wrote: ↑Mon Nov 20, 2023 7:22 am
Awesome, could rip it off and sell
Feel free
Re: [WIP] BMW Z3
Posted: Mon Nov 20, 2023 8:30 am
by Alibro
andybpowell wrote: ↑Sun Nov 19, 2023 6:15 pm
Since I'm going over to a zombieverter from my own controller now that I'm swapping the LEAF motor for the GS300h I was going to just put a parallel capacitor and resistor in series with the contactor as an economiser circuit but having tried it I wasn't happy with the heat of the resistor or the energy saving it worked fine but since I'm just playing I thought I try something else, I have been using Buck converters in small circuits for years as they are cheap as chips and very energy efficient so I thought why not use one to output 12v at switch on then reduce to a holding voltage for the contactor so I did; This is the circuit diag for the one I'm using it's a variable voltage version and the output voltage is set using a variable resistor r2 in the diagram
Capture.JPG
if you set your hold voltage for your contactor using the standard circuit using the variable resistor(R2) then put a suitable sized resistor in parallel with R1 until the output is 12V then add an electrolytic capacitor in series with this resistor when you apply power the output voltage will peak at 12 then reduce down to the hold voltage that you set the time taken determined by R1,R2 and the new resistor and capacitor I'm still tweaking the values of the resistors and capacitor but it works really well and it's cheap the last batch of these buck converters I bought cost about £1.60 each.
This circuit is currently using just over 2 Watts per contactor my previous circuit using a parallel capacitor and resistor in series with the contactor was using around 7 Watts and un-economised about 28 Watts I still need to adjust the resistor and capacitor values but so far it's not a bad afternoons tinkering
How low would you be comfortable to reduce the voltage? I tried switching VW eGolf contactors using 10V and they seemed happy to switch at that but after welding several of them I decided to switch to Kilovac's https://s.click.aliexpress.com/e/_DmFk0Ib
I don't know if these are genuine or not but they weigh the same look and feel identical and have the same copper posts. I'll keep monitoring them but so far no probs. Note the "genuine" ones I am comparing them to were used ones from Israel I bought a few years ago but one of them was faulty so I don't trust the second.
Re: [WIP] BMW Z3
Posted: Mon Nov 20, 2023 9:16 am
by andybpowell
Alibro wrote: ↑Mon Nov 20, 2023 8:30 am
How low would you be comfortable to reduce the voltage? I tried switching VW eGolf contactors using 10V and they seemed happy to switch at that but after welding several of them I decided to switch to Kilovac's https://s.click.aliexpress.com/e/_DmFk0Ib
I don't know if these are genuine or not but they weigh the same look and feel identical and have the same copper posts. I'll keep monitoring them but so far no probs. Note the "genuine" ones I am comparing them to were used ones from Israel I bought a few years ago but one of them was faulty so I don't trust the second.
I'm using gigavac contactors and the recommended hold voltage for mine is 2.6v you still need 12v to close them in the first place
Has anyone tried a peak and hold driver yet for contactor control? Something like an LM1949. This should be a low EMI / noise solution.
Could possibly use the STM32 to go on for a time then switch to pwm to hold them. Might be noisy / ground bouncey though.
Re: [WIP] BMW Z3
Posted: Thu Nov 23, 2023 8:35 pm
by andybpowell
just made up a controller to do the things that the Zombieverter currently doesn't the power steering pump control, the BMW f series gearlever and a few other things though there's no reason why it can't maybe something for the future anyway it's not exactly JLPCB but it does the job thought someone might be interested
Re: [WIP] BMW Z3
Posted: Fri Nov 24, 2023 2:58 pm
by andybpowell
This is the final version of my economiser using a buck converter using a much smaller one now so I can finish my front battery box and get on