openinverter forum

also, i decided to go with custom busbars for my batteries, instead of cable, since they will be VERY inaccessible when installed and it will make me worry a bit less about my crimps

Yes, bussbar >>> cables!!!

Busbars!

Very professional

battery reconfiguration done, and installed under the truck. TDL is still very long.

Again, this is a very modest battery pack, @ ≈7kWh, that I chose for it's low cost and small packaging that gets me to a 96s pack.

Batteries with all BMS leads and busbars installed: then back in their enclosures: installed under the truck, not noticeable at all: My K100 cafe project that's been a fun distraction: Before a test spin i need the EVBMW Leaf VCU wired up and some HV junction box stuff mocked up. Also HV cables run.

You said low cost. May I ask how much for the modules? Might go your route.

RetroZero wrote: ↑Fri Jul 30, 2021 9:05 am You said low cost. May I ask how much for the modules? Might go your route.

They sold out after a few weeks but they were $100 each. Mercedes L09-1 modules, cells made by Li-Tec in Germany.

At 880Wh new, with the diecast enclosure they come in, I thought it was a good deal. I bought 16 and am only using 8 at first. depending on my range i may add the other 8 in parallel. they did take a decent amount of work to make usable, as you can see in the thread. And when running these in a 96S 1P config each cell tab is carrying full current. So, we'll see how that goes...

Goodnight to know. With the golf/caddy space and weight is critical, and then the cost. Will wait to see what range you get. For now I have mountings to make

made a little more progress before paternity leave ended.

yet again, more laser cut parts from Send Cut Send. Chevy Volt Charger bracket and a bracket for the Leaf acc pedal
Leaf pedal proto and final bracket. GOT to design > proto > test > design > proto > make installed in truck: charge bracket mount to Leaf motor: Installed:
Now I need to get to my High Voltage Junction Box and control system wiring.

HVJB work has begun:

This is alittle large but i plan for it to contain:

1. HV fusing + distro (DCDC & Charger)
2. pos & neg contactors
3. Isa Shunt
4. precharge relay and resistor

I've 3-d printed mounts so it will fasten directly to the top of the EM57 inverter.
Then the DC input to the inverter will be sealed via this 3-d printed assembly

big update:

HV Junction Box is done, installed, and connected to batteries VCU is wired to HVJB and leaf inverter. VCU CAN jumpers from header 1 to 2. to connect the Inverter CAN with ISA Shunt communication to pins on HVJB header where ISA shunt resides. I plan to bring this up in the Leaf VCU support thread. It's my understanding that the ISA Shunt and Leaf Inverter share the same CAN bus. I'll have to look at Damien's code to confirm. Charge inlet mounting designed and done 12s battery charger/balancer used to check cell voltages designed and printed a 12v battery tray for a LiFePo4 35Ah

You are on the burn. Nice progress

RetroZero wrote: ↑Wed Oct 27, 2021 4:17 pm You are on the burn. Nice progress

my god i wish it felt like that, haha. I have very little time to get this going and there is still SO much to do.

appreciate the support though!

my doc for tracking wiring: https://docs.google.com/spreadsheets/d/ ... p=drivesdk

i plan to do a full schematic at some point. perhaps in a Miro board.

Kind of a big milestone. Full Voltage in the Junction Box.

Slow goes the progress.

Volt charger and DCDC mounted.

after a bunch of test wiring, then more code review and trouble-shooting, I have a spinning motor!

Precharge works great, Acc pedal calibrated. Next up will be further refinement of the low voltage wiring, and then on to getting my Volt DC-DC and Charger working. Also wiring the Leaf BMS.



and my wiring:

I guess if the motor can spin, the wheels can spin too

Nice

changing my BMS strategy. Was intending on using the Nissan Leaf BMS, but have since decided to go the Simp BMS + Tesla route.

You may wonder how, if I'm not using Tesla modules. Well i just bought a bunch of used Model S/X BMS boards off ebay and am going to wire them to my cells. Combining 2 boards get's me the 12S i need for each of my mercedes modules.

CAD: prototyping

Nice, bought a gen1 volt bms to do the same thing. never found a good price for Tesla slave boards, how much did you get the full set for?

Bratitude wrote: ↑Thu Apr 07, 2022 3:01 am Nice, bought a gen1 volt bms to do the same thing. never found a good price for Tesla slave boards, how much did you get the full set for?

So, i knew there would be a bunch of loose model S/X boards out there because of so many people using aftermarket BMSs +adapter boards for stationary, or other, use cases. StealthEV who makes an adapter board for these modules had hundreds of these in stock, which they sold to me for $25ea.

So for 16 modules, needed for a 400V system, plus the cost of the Simp BMS:

Simp BMS from kitoffgrid (only place that would ship to the US): $578
Model S/X modules from StealthEV: $400
BTW, I'm hoping to get it set up to share my powertrain contactors and ISA shunt.

I compared this to the Orion BMS for a 96s system at $2000.

Here is my first 12s sub-module test setup, contains 2 tesla boards: They will mount to the side of my batteries like so:

Nice going

What kind of 3d printer are you using to print those housings?