openinverter forum

Hello All,

I first came across this forum about two years ago and after reading through multiple EV projects and watching some of your videos, I got hooked.
After picking up a clean bmw e39 520i and getting a GS450h from a breakers yard in Monaghan, I was ready to make a start. Then I realised I didn't want to start this project without a workshop, this took me another 12 months to build.

Over the Christmas break I got cracking on this project and removed the engine, gearbox and diff. I'm currently working on transmission brackets and adapting a BMW auto selector. Hoping to have wheels spinning in the next few months.

I still have a few parts to source: Batteries, Charger, BMS, Zombie VCU, ISA shunt, Vacuum Pump, Power steering, Charging plugs and Sockets.

I have a bit done and a lot more to do.

Welcome to the party

What year is your BMWer?

How are you getting on? I'm just starting a similar project to fit a gs450h g'box to an old classic that also needs a fairbit of resto. I'm in Kildare, so not a million miles away from you.
Best of luck with your bmw, I'll be watching with interest.

I'd love to know what RPMS you have achieved with the gs450h and at what voltages, thanks

Jacobsmess wrote: ↑Mon May 15, 2023 7:39 am I'd love to know what RPMS you have achieved with the gs450h and at what voltages, thanks

If it helps, in my build I've had the car to a little over 90mph which was around 6000rpm. My system is 353volts full charge but probably around 300v on that run.

PatrcioEV-ATX wrote: ↑Tue May 16, 2023 7:10 pm If it helps, in my build I've had the car to a little over 90mph which was around 6000rpm. My system is 353volts full charge but probably around 300v on that run.

It does, is that 6000rpm of mg2? When you say 300V is that due to sag and low charge or a generally lower voltage system?

Jacobsmess wrote: ↑Tue May 16, 2023 8:17 pm It does, is that 6000rpm of mg2? When you say 300V is that due to sag and low charge or a generally lower voltage system?

Yes, MG2. The 300v was my level of charge, but it definitely can keep that power coming as the voltage sags even lower under load.

PatrcioEV-ATX wrote: ↑Thu May 18, 2023 2:18 pm Yes, MG2. The 300v was my level of charge, but it definitely can keep that power coming as the voltage sags even lower under load.

Thanks and yes useful, even at 8500 rpm of mg2, my stupidly geared diff would only just achieve 80mph at the 1.9 high gear.

I guess I either need to change my rear axle, differential, final gearing or just go with a leaf motor bolted to the gearbox. Unless I could use the boost stage of the lexus/Prius inverters to get up to 650V by increasing the IGBTs, although I'm no electronics engineer and have no idea what this may then lead to.

Welcome kev, Ive an e39 ga450h touring project myself. lacking a workshop, at least one close to the house. So I'm not tearing into the car until I've all parts.
you using zombieverter? keep us posted.

Progress is Slow but steady

MG1 Locking plate removed

inverter and outlander charger in position

I am in the process of building a battery box to hold 12 BMW Phev batteries . Three under inverter and charger and then three stacks of three to the front.

Cad drawings of transmission, inverter & charger brackets

Auto shifter, Propshaft & Transmission rear mounting

Wish my transmission came with the mounting bracket, currently trying to source one or fabricate something.
How did you go about aligning the output shaft flange?

The car is up on blocks and is reasonably level, the floor is in good shape. So I measured from ground to the centre of the Propshaft beside the bearing to get my target centre point and I also made sure that the transmission was level using the bell housing vertical front surface and a spirit level. It took three attempts with the brackets, the first ones were 28mm, then 50mm and finally decided on 40mm

Making slow progress, got the HV cables for the sbox, inverter & battery box sorted, happy them them. Just having issues getting the zombie and sbox to communicate.
Still haven't got to experience the motor first spin
Can anyone advise what parameters will run the Zombie without a shunt or sbox when manually switching pre charge and main HV
Would it be udcsw ,udcmin & UDC lim at zero

I have attached the STL files for the inverter plugs.

The STLs for those parts available? I like the needing of bolts to get to the HV

Bigpie wrote: ↑Thu Mar 07, 2024 12:42 pm The STLs for those parts available? I like the needing of bolts to get to the HV

Agreed id appreciate those they look neat

Nice prograss , like conversion

My zombie and the Sbox are happily communicating and the wheels are now spinning. So the project is moving the right direction. The next challenge that I am facing is with the oil pump. It's not running correctly , one second run then it stops for twoseconds then it runs again for about one second
I have changed the bearings, no change
Then I bought a second pump controller, no change.
Battery at fully charged at 13 volts.
I am now thinking maybe my wiring harness which I made up is wrong and I have the three wires Red, White & Black wires hopefully in the wrong positions.
Does anyone know what the correct positions for these wires should be.

W
V
U

All suggestions welcome

Red to W, white to V black to U.

Do you have the controller wired correctly also?

1 blue
2 green
3 yellow
4 red
5 black

Then the big connector on the controller needs the black PWM wire to the zombie and 12V with the controller body being grounded.

Thanks for the help with the oil pump wiring.
The problem was that the ground wire was to small.

I have been trying to get my Mitsubishi charger set up with the phev batteries and sbox.
I have the Type 2 port and the Zombie is seeing the charging Cable but haven't been able to get the zombie to go into charge mode.
If this is working successfully in a project I would really appreciate if the zombie parameters required be shared or sent to me by PM.
I have been playing with this for weeks and have ran out out of ideas
General set up
3. Interface. CPC
4. Chargermodes. Outlander
9. Charger Can. CAN2
62. Chgctrl. Enable
87. Out1Func OBC Enable
95.GP12VInFunc OBC Enable
97. GPA1Func. Prox Pilot
99. Pot thresh. 2500

When the granny charger is plugged in the Pilot value is at 2220 and plugged out the value is 2650.

Share your parameters please

The CPC is the only device connected to the charge port. It needs to be setup to the user manual: https://docs.google.com/document/d/1fxL ... ue&sd=true

The Zombie will go into charge mode when commanded via CAN by the CPC.

Do not have anything else set to charge related inputs. Possibly the Outlander charger currently does not work as it should, the up coming release will fix alot of compatibility problems.