EV car conversion hardware

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Cookie6000
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Re: EV car conversion hardware

Post by Cookie6000 »

I had this in my thread but I thought I would add it in here to the Hardware thread. DC/DC converter I am using is the TDK unit from the AZD Transit Connect conversions. I gathered a lot of the info from various locations including from lars rengersen who fitted one to his Amazon.
20200913_113327v2.jpg
100A water cooled (I did read somewhere that it was 80A if air cooled, tbc).The control pins:
Pin 1 is to disable. Pulling the enable pin to ground, turns off the power supply. Good direction from Lars here was to enable Pin 1 only after precharge is complete as you want the precharge energy to go do the inverter capacitors and nothing else. I actually tried this out inadvertently earlier and sure enough, the main connector wont close if the DC/DC is operating.
Pin 3 controls the output voltage. Not connected it is 14.5v. Pulled to ground is 13.8v.
Pin 6 is a fault pin. Not connected and have not found anyone who uses it yet.
The connector can be found on Alibaba - 90980-11658 10 hole Transmission solenoid valve plug for TOYOTA
http://www.kinkong-connector.com/produc ... ID898.html
90980-11658.JPG
More info here on the unit.
https://www.diyelectriccar.com/threads/ ... ter.91682/
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Re: EV car conversion hardware

Post by Doig5710 »

Hey looks like a good DC-DC option just wondering if there was a part number to google/search for?
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Re: EV car conversion hardware

Post by jcwright45 »

Anyone have any recommendations for water based cabin heaters besides the Nissan Leaf version? I don't want to rip out my dashboard to install a matrix unit if I don't have to. Looking for something already hacked, tested, and possibly on the inexpensive side.
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Re: EV car conversion hardware

Post by bobby_come_lately »

jcwright45 wrote: Sat Sep 19, 2020 5:28 pm Anyone have any recommendations for water based cabin heaters besides the Nissan Leaf version? I don't want to rip out my dashboard to install a matrix unit if I don't have to. Looking for something already hacked, tested, and possibly on the inexpensive side.
Can't offer you tested but I am worked on modifying a cheap engine pre-heater from AC to DC. Notionally 2kw. Like this one, but only cost me about £20-25 (Chinese site I think - Aliexpress maybe?) https://www.ebay.co.uk/itm/2kw-Engine-C ... 1955251248.

Has 19mm barbs. Opened it up and disconnected the motor then removed the rotor and impeller and filled the gap with high temperature silicone. Planning to use it with one of the cheap VAG-clone pumps as a test.
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Re: EV car conversion hardware

Post by Cookie6000 »

Doig5710 wrote: Fri Sep 18, 2020 8:47 am Hey looks like a good DC-DC option just wondering if there was a part number to google/search for?
Ah, sorry. I forgot to add in the vital piece. the TDK 9M68 14B227 AB. Here is the label
20200925_085839.jpg
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Re: EV car conversion hardware

Post by Hank »

tom91 wrote: Tue Jun 23, 2020 8:54 am I am also working on some adapters that we hope to sell at Zero-EV. Utilising gland components to work with 70mm2 or 50mm2 shielded cables.
Did you ever get those made?
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Re: EV car conversion hardware

Post by tom91 »

Hank wrote: Wed Oct 07, 2020 3:15 am Did you ever get those made?
Getting close now, we have some samples made. However finding the right grounding springs and gland items is proving a bit of a pain. So probably ending up making everything bespoke.
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Re: EV car conversion hardware

Post by mdrobnak »

Cookie6000 wrote: Fri Sep 25, 2020 8:04 am
Doig5710 wrote: Fri Sep 18, 2020 8:47 am Hey looks like a good DC-DC option just wondering if there was a part number to google/search for?
Ah, sorry. I forgot to add in the vital piece. the TDK 9M68 14B227 AB. Here is the label
20200925_085839.jpg
TDK - Not exactly making cassette tapes any more! Wow. Definitely an unexpected branch name to see.
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Re: EV car conversion hardware

Post by arber333 »

mdrobnak wrote: Thu Oct 08, 2020 1:46 am
TDK - Not exactly making cassette tapes any more! Wow. Definitely an unexpected branch name to see.
Ya, TDK be making a lot of electronics, it is just diversified so you dont exactly know which division works on that . Even Volt gen1 DCDC is made by them.
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Re: EV car conversion hardware

Post by DarkwingDuck »

Cookie6000 wrote: Fri Sep 25, 2020 8:04 am
Doig5710 wrote: Fri Sep 18, 2020 8:47 am Hey looks like a good DC-DC option just wondering if there was a part number to google/search for?
Ah, sorry. I forgot to add in the vital piece. the TDK 9M68 14B227 AB. Here is the label
20200925_085839.jpg
I just bought the ford escape hybrid version, 8M68 14B227 AB, supposedly rated for 210-397V HVDC and with 1,5 kW max output(?). I'll try it out later and report the results here
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Re: EV car conversion hardware

Post by muehlpower »

Hello, I have an air conditioning compressor from a Golf GTE, like the one installed in the E-Golf and the Passat GTE. The parts are cheap to get on ebay. Unfortunately I haven't got it working yet. The inverter is integrated and controlled via the LIN bus. Unfortunately the protocol is missing. Does anyone have the option to create a data log of a running compressor in the car?
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Re: EV car conversion hardware

Post by arber333 »

muehlpower wrote: Mon Oct 12, 2020 12:14 pm Hello, I have an air conditioning compressor from a Golf GTE, like the one installed in the E-Golf and the Passat GTE. The parts are cheap to get on ebay. Unfortunately I haven't got it working yet. The inverter is integrated and controlled via the LIN bus. Unfortunately the protocol is missing. Does anyone have the option to create a data log of a running compressor in the car?
I also have a Golf GTE inverter and charger at home and i will have to start exploring for reverse engineering.
Anyone has any data on the GTE hybrid charger? I know it is 3.3kW and single phase. I think it needs some form of CAN signals.
On page 37 of this document i found some info on how charging works: https://vwgpaintandbody.co.uk/wp-conten ... at-GTE.pdf
It seems that this VCU transmitts data to charger. Anyone has GTE to spy signals from? Or anyone has schematic for charger LV connector?
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Re: EV car conversion hardware

Post by arber333 »

Here are some brake boost pumps for which i know are certified to pass TUV.
MES-DEA 70/6E2
https://evshop.eu/en/vacuum-pumps/58-mes-dea-706e2.html
https://evshop.eu/en/index.php?controll ... achment=23

Hella UP28
Found in various Audi, VW and Volvo cars
https://www.hella.com/microsite-electro ... s-116.html
http://hellahd.com/index.php/default/el ... roduct-11/

Hella UP30
I found that in a Renault Megane car. I use this in my conversion and is quite powerfull.
https://www.hella.com/microsite-electro ... p-117.html

The real problem i see is using brake switch. I think we would need more variation of them.
I had a problem with Dracarys switch. It is easy to use, but it is terribly unreliable.
https://www.amazon.co.uk/Dracarys-Acces ... B07H9664YM
It locks off at random. I found it is good to spray some WD40 into the switch before installation. But still when it goes dry membrane still sticks. I will try MIG welding spatter spray next...

Then i will replace it with this: PSF109S-81-330 switch
https://uk.farnell.com/multicomp/psf109 ... PSF%20109S

There is also this switch available: Volvo Booster Vacuum Switch 30645493 or 30645383. I need to test it yet...
https://www.fcpeuro.com/products/volvo- ... o-31265825
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Re: EV car conversion hardware

Post by Cookie6000 »

arber333 wrote: Thu Oct 15, 2020 6:54 pm The real problem i see is using brake switch. I think we would need more variation of them.
I had a problem with Dracarys switch. It is easy to use, but it is terribly unreliable.
https://www.amazon.co.uk/Dracarys-Acces ... B07H9664YM
It locks off at random. I found it is good to spray some WD40 into the switch before installation. But still when it goes dry membrane still sticks. I will try MIG welding spatter spray next...

Then i will replace it with this: PSF109S-81-330 switch
https://uk.farnell.com/multicomp/psf109 ... PSF%20109S

There is also this switch available: Volvo Booster Vacuum Switch 30645493 or 30645383. I need to test it yet...
https://www.fcpeuro.com/products/volvo- ... o-31265825
Hey arber, do you think the Dracarys would be more reliable with a silicone based lubricant used in vacuum systems it is it just an inherently flawed switch? I am about to swap out the hydraulic system on the Audi for the vac boost using the UP28 pump and just need to buy the switch. I may do the same as you and look at testing in the volvo switch in my system.

When I get the cash and one comes available at the right price, I am going to run some tests on the Bosch iBooster fitted by a number of manufacturers, including Tesla, also. I was contacted by someone who has it fitted to their Mk2 Golf and it works very well. Not sure of the redundancy side of things though.

Edit: I have been looking around for more alternatives and came across the Bosch 0265 005 321 Vacuum Brake Servo Sensor from the Zafira C.
brake-booster-pressure-sensor2.jpg
https://www.ebay.co.uk/itm/Opel-Zafira- ... SwboFeWXco

You can see here it fits directly into the vac boost servo and the vac pipe out. They all seem to be out there for between €15-€30 so, I might as well get one and give it a test.
ZafiraBoschVacSensor.jpg
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Re: EV car conversion hardware

Post by arber333 »

Cookie6000 wrote: Tue Nov 03, 2020 2:46 pm Hey arber, do you think the Dracarys would be more reliable with a silicone based lubricant used in vacuum systems it is it just an inherently flawed switch? I am about to swap out the hydraulic system on the Audi for the vac boost using the UP28 pump and just need to buy the switch. I may do the same as you and look at testing in the volvo switch in my system.

When I get the cash and one comes available at the right price, I am going to run some tests on the Bosch iBooster fitted by a number of manufacturers, including Tesla, also. I was contacted by someone who has it fitted to their Mk2 Golf and it works very well. Not sure of the redundancy side of things though.

Edit: I have been looking around for more alternatives and came across the Bosch 0265 005 321 Vacuum Brake Servo Sensor from the Zafira C.
brake-booster-pressure-sensor2.jpg
https://www.ebay.co.uk/itm/Opel-Zafira- ... SwboFeWXco

You can see here it fits directly into the vac boost servo and the vac pipe out. They all seem to be out there for between €15-€30 so, I might as well get one and give it a test.
ZafiraBoschVacSensor.jpg
For sure Dracarys switch is sticking up on ordinary car relay switching. Load is nothing much, maybe 300mA. After a while it works, but suddenly it sticks and thats it. Not so gentle tap on the switch case will release it. I tried to apply WD40, pneumatic lubricant and welding anti spatter spray. Eventually situation repeats itself. I strongly dissuade anyone from buying it.
On the other hand the same kind of switch in my Mazda works from 2016 without any issues. Go figure...

That looks interesting since i got my UP28 from Zafira. Should have taken the whole pneumo lines with me...
Care to test it under vacuum?
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Re: EV car conversion hardware

Post by arber333 »

I finally replaced the pesky Dracarys brake switch. It was sticking when operating and i couldnt do anything worth to get it working reliably.
I replaced it with Volvo XC90 switch. See here...
https://www.eeuroparts.com/Parts/178401 ... -31400608/

Connector is Bosch of some variant...
IMG_20201110_175536.jpg
One line goes to GND and the other one connects to the relay which is powered by fused 12V on the other side.

It has 3 ports. Each port has its own non-return valve. Two ports (1, 2 from leftmost going CCW) vere setup for underpressure flow and one (3) is setup for overpressure flow. This lets me connect the hose directly to 1 and 3 with one port (2) in the air.
IMG_20201110_172336.jpg
You can see the 1 port is connected to the pump with 3 port going to the cylinder booster.
For the hose i used blue gas hose since it has double sleeves.
IMG_20201110_172312.jpg
I fixed it temporarily directly to brake booster lines.
So far it works without any issues. It keeps vacuum surprisingly long.

Edit: yes, now I can confirm Volvo vacuum switch is definitely worth using. Not only it has a good reliable sensor it also has one way valves built in. Essentially it is a plug and play item. I highly recommend it.
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Re: EV car conversion hardware

Post by Alibro »

Has anyone tried one of the Chinese brake vacuum boost kits available?
https://www.ebay.co.uk/itm/372899120153
Are we safer to stick with the Audi vacuum pump? 8E0927317
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Re: EV car conversion hardware

Post by Cookie6000 »

I would rather stick to the OEM's myself.
By the way, got all my brake boost parts including the Bosch 0265 005 321 Vacuum Brake Servo Sensor so plan this week to swap the servo from hydraulic to vac, get the UP28 in, test with the sensor and this vac reservoir PN 443131541 and report back.
These are from any number of VAG's from the mid to late 00's and will give you an extra three presses of the pedal after loss of power.
VacReservoir.JPG
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Re: EV car conversion hardware

Post by Alibro »

Agreed Cookie, I wouldn't feel confident relying on a Cheap brake booster so OEM it is then.
I already have the reservoir from my Freelander which I think is similar and would like to retain if it works but will order the other parts.
Thanks for the part numbers.
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Re: EV car conversion hardware

Post by Stephen Darbey »

Hi Jnsaff.

Can you PM me please re Contactors

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Re: EV car conversion hardware

Post by johu »

Split off the vacuum switch discussion: viewtopic.php?f=9&t=1211
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Re: EV car conversion hardware

Post by jon volk »

Has anyone come across what the Volvo EPAS pumps want to see doe CAN input? Running in failsafe now and it’s a bit overboosted at higher speeds. Feels perfect when low speed maneuvering but as with everything, adjustability is better.

I’ve searched a bunch and can’t find anything relevant.
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Re: EV car conversion hardware

Post by arber333 »

jon volk wrote: Wed Nov 25, 2020 6:48 pm Has anyone come across what the Volvo EPAS pumps want to see doe CAN input? Running in failsafe now and it’s a bit overboosted at higher speeds. Feels perfect when low speed maneuvering but as with everything, adjustability is better.

I’ve searched a bunch and can’t find anything relevant.
Here is one discussion
https://www.diyelectriccar.com/threads/ ... ost-180484
Try one of the last posts, i think i saw CAN telegram mentioned and some references to other forums.
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Re: EV car conversion hardware

Post by jon volk »

Thanks. I read through that one before and could have sworn there wasn’t anything besides the CAN wiring references. Looks like I’ve got some breadcrumbs to work with.
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Re: EV car conversion hardware

Post by Cookie6000 »

Hi all

Just something I stumbled across today. I was out in the car and showing it to my local mechanic who also specialises in rally and track 1960's Mini's. He showed me what is used as a weapon of choice in small rally cars these days and according to him, takes an incredible amount of abuse and very rarely fails... unless you have a big crash :lol: . The Corsa C steering column, motor plus its own ECU which just needs 12v. Very tidy unit and it even fits the limited space offered under the dash of a 60's Mini. Loose when you are doing slow turning (they like it especially for autotest cars) and it tightens up when you are at speed. They usually hook it up to a speed sensor on a rear wheel but like my own, I could take the feed from the elec speedo pulse coming from the gearbox.
Corsa C Steering.png
Corsa C Steering ID.png
https://www.ebay.co.uk/itm/13136672-ste ... SwmtFfrEgQ
Has anyone fitted one of these before? They have come way down in price and from looking at eBay, they sit between £60-£150 which is incredible. They used to sit around £400. I am going to pick one up and see if it is a viable option for the 8e to remove the constant whine from the TRW Zafira pump. I may even be able to maintain the Audi's rack and be able to remove all hydraulic to free up space.
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