openinverter.org wiki - User contributions [en]

BMW i3 Inverter

2024-05-11T16:55:20Z

CJW: Updated series resistor value for pin 35 on Harwin connector

BMW I3 inverter
[[File:BMW I3 inverter.jpg|thumb|BMW I3 inverter]]

Forum thread: https://openinverter.org/forum/viewtopic.php?p=23214#p23214

BMW i3™ inverter drop-in board Available

https://openinverter.org/shop/index.php?route=product/product&product_id=72

'''<big>Overview</big>'''

There are 2 variants of the i3, the standard i3 with motor power rated at 125kW and the i3s rated at 135kW.

There are 2 subvariants, as REX versions have an additional 25kw inverter and onboard generator.

Power stage: [https://www.infineon.com/dgdl/Infineon-HybridPACK2_Power_Modules-PB-v01_00-EN.pdf?fileId=db3a3043353fdc16013557f17ce67b60 Infineon FS800R07] IGBTs rated for 800amps 650v

'''<big>Openinverter Drop-in Board</big>'''
[[File:Openinverter i3 drop-in board.jpg|thumb|300x300px|Openinverter i3 drop-in board]]
The drop-in board houses the openinverter, generates 32V for the gate driver board, communicates via SPI with the gate driver board to obtain voltage and temperature readouts, and provides outputs to operate contactors. See bottom of the page for list of modifications required for these boards to work. Pinouts for the three connectors on this board below.

{| class="wikitable"
|+ Pinout for Ampseal Plug
|-
! Pin No !! Assigniment !! Description
|-
| 1|| 12V ||
|-
| 2|| BRAKE_IN ||
|-
| 3|| PRECHARGE_OUT ||
|-
| 4|| CANL ||
|-
| 5|| CANH ||
|-
| 6|| DCSW_OUT ||
|-
| 7|| FORWARD_IN ||
|-
| 8|| REVERSE_IN ||
|-
| 9|| 5V (OUT) ||
|-
| 10|| RESOLVER_S2/ENCODER_A || Sin Hi
|-
| 11|| GND ||
|-
| 12|| RESOLVER_S1 || Sin Lo
|-
| 13|| THROTTLE1 ||
|-
| 14|| THROTTLE2 ||
|-
| 15|| RESOLVER_R1 || Ex Hi
|-
| 16|| RESOLVER_S3/ENCODER_B || Cos Hi
|-
| 17|| MTEMP+ ||
|-
| 18|| MTEMP- ||
|-
| 19|| RESOLVER_S4 || Cos Lo
|-
| 20|| EMCYSTOP_IN ||
|-
| 21 || GND ||
|-
| 22|| RESOLVER_R2 || Ex Lo
|-
| 23|| START_IN ||
|}

{| class="wikitable"
|+Pinout for Gate Driver Board
!Pin No
!I/O
!Description
!Notes
!
!Pin No
!I/O
!Description
!Notes
|-
|1
|
|
|
|
|21
|
|GND Switching Mosfets ?
|
|-
|2
|I
|32V in
|
|
|22
|
|GND Switching Mosfets ?
|
|-
|3
|I
|32V in
|
|
|23
|
|
|
|-
|4
|I
|IGBT A HI
|
|
|24
|
|
|
|-
|5
|I
|IGBT A LOW
|
|
|25
|
|
|
|-
|6
|I
|'''CS (ADC)'''
|
|
|26
|
|GND IGBT Driver ground
|
|-
|7
|I
|'''SDI'''
|
|
|27
|
|GND IGBT Driver ground
|
|-
|8
|I
|'''SDO'''
|
|
|28
|
|GND IGBT Driver ground
|
|-
|9
|I
|'''SCK'''
|
|
|29
|
|GND IGBT Driver ground
|
|-
|10
|I
|IGBT B HI
|
|
|30
|
|GND IGBT Driver ground
|
|-
|11
|I
|IGBT B LOW
|
|
|31
|
|GND IGBT Driver ground
|
|-
|12
|I
|IGBT C HI
|
|
|32
|
|GND IGBT Driver ground
|
|-
|13
|I
|IGBT C LOW
|
|
|33
|
|5V IGBT Driver Power
|
|-
|14
|
|
|
|
|34
|
|5V IGBT Driver Power
|
|-
|15
|
|
|
|
|35
|I
|IGBT PSU on (5V or 12V)
|
|-
|16
|O
|IGBT DRIVER UVW Upper Ready
|
|
|36
|O
|IGBT Driver Fault
|
|-
|17
|O
|IGBT DRIVER UVW Lower Ready
|
|
|37
|I
|5V LEM Current sensor Power
|
|-
|18
|O
|Current Sense C Signal
|
|
|38
|
|GND Current sensor Ground
|
|-
|19
|O
|Current Sense B Signal
|
|
|39
|
|GND Current sensor Ground
|
|-
|20
|O
|Current Sense A Signal
|
|
|40
|
|GND Current sensor Ground
|
|}

Note: Pin 35 is connected to a [https://openinverter.org/forum/viewtopic.php?p=69712#p69712 mosfet gate on the gate driver board] and has been tested with both 5V and 12V.

'''<big>Motor Resolver & Temperature Sensors</big>'''

12-pin PCB header to connect to the motor sensors is an ERNI MiniBridge, part number 294920

Wire colours to pin allocation below determined by schematic and multimeter trace, with resolver coils and temperature sensors checked for resistance. Confirmed with motor bench test. [[File:ERNI Minibridge Connector.jpg|thumb|ERNI Minibridge Connector. Dots indicate pin 1.]]
{| class="wikitable"
|+Pinout for ERNI Microbridge
!Pin No
!Colour
!Description
!Notes
|-
|1
|Brown
|Sin Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω.
|-
|2
|Blue
|Sin Lo
|-
|3
|Yellow
|Ex Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω
|-
|4
|Green
|Ex Lo
|-
|5
|Red
|Cos Hi
| rowspan="2" |Twisted pair. 13.6 - 20.4 Ω
|-
|6
|White
|Cos Lo
|-
|7
|Blue
| rowspan="2" |Temperature
Sensor
| rowspan="4" |From BMW Service Technical Training Manual - I01 High-voltage Components:
There are two stator coil temperature sensors.

The rotor temperature is determined using readings from the stator temperature sensors.
|-
|8
|Grey
|-
|9
|Red
| rowspan="2" |Temperature
Sensor
|-
|10
|Grey
|-
|11
| -
|Unused
| rowspan="2" |These wires terminate in one of the six pin connectors in the motor housing. There is nothing connected to them.
|-
|12
| -
|Unused
|}

[[File:Mod 1. - Close SJ3.jpg|thumb|Mod 1. Close SJ3]]

'''<big>Modifications required to drop-in boards</big>'''

Five modifications are required for the drop-in boards to work, plus an additional one if using CAN communication.

'''Mod''' '''1. Close SJ3 on the openinverter board with solder'''

This enables SPI communications by assigned Pin 4 on JP2 as the MOSI line. [[Mini Mainboard|Additional explanation here]].

'''Mod''' '''2. Motor Resolver & Temperature Sensor Adaptor Boards'''
[[File:Ampseal board.png|thumb|300x300px|Mod 2. - Ampseal adapter board]]
[[File:ERNI Microbridge adapter board.png|thumb|300x300px|Mod 2. - ERNI Microbridge adapter board]]
A [https://openinverter.org/forum/viewtopic.php?p=63903#p63903 pair of adaptor boards] (see also images to right) are available and shipped with the current drop-in boards. These enable the ERNI Microbridge connector from the resolver and motor temperature sensors to be connected to the required pins on the Ampseal connector. Design files for these boards will be posted on github at some point - if you need a copy in the meantime contact user 'CJW' or post on the i3 controller hacking thread.

'''Mod''' '''3.''' '''Code Update for Gate Driver Board - SPI Commication'''

The BMW i3 gate driver board communicates the DC bus voltage (ie traction battery voltage) and IGBT heatsink temperatures to the Openinverter via SPI.

On the Openinverter mini mainboard, pin 17 on JP2 is normally used as an 'Error Output'. When used with the BMW i3, this pin must instead be used for the SPI Clock signal.

To avoid the clock signal being pulled high or low by the pin acting as an Error Output, find this section of code in vehiclecontrol.cpp:<syntaxhighlight lang="cpp">
//Brake pin is used as SPI_MISO
DigIo::brk_out.Configure(GPIOC, GPIO5, PinMode::INPUT_FLT);

</syntaxhighlight>and insert these lines of code below it, to disable the Error Output:<syntaxhighlight lang="cpp">
//Disable err_out so it doesn't pull the clock signal up or down
DigIo::err_out.Configure(GPIOC, GPIO10, PinMode::INPUT_FLT);
</syntaxhighlight>

[[File:Mod 5. - Gate driver PSU.jpg|thumb|Mod 5. - Gate driver PSU power pin]]

'''Mod 4.''' '''Check solder connections on the drop-in board'''

The 40 pin surface mount Harwin connector to the gate driver board may have dry joints or shorts.

'''Mod 5.''' '''Gate driver PSU power pin'''

Pin 35 of the Harwin connector to the gate driver board is not connected to anything. Testing indicates this must be powered for the gate driver to work, at least on some boards. The motor has been run successfully with [https://openinverter.org/forum/viewtopic.php?p=70213#p70213 5V to this pin via a 100 Ohm resistor from the adjacent pin 34], which receives power from the openinverter's 5V supply. Some earlier notes in the i3 hacking thread suggest it may also have been tested with 12V.

'''Mod 6. CAN slew rate pin'''

This pin is floating but needs to be [https://openinverter.org/forum/viewtopic.php?p=41110#p41110 tied to ground with a resistor] if CAN communication is used. Can be any value from like 0R to 20k, the value controls the slew rate.

'''<big>Openinverter Parameters</big>'''

[https://openinverter.org/forum/viewtopic.php?p=69749#p69749 This initial set of parameters] have been used for successfull bench testing a motor with a pair of lead acid car batteries. Will update and eventually post a full set of parameters here once the motor is properly set up and has been tested with a high voltage battery.

'''<big>Future Development</big>'''

List of tasks to be completed to enable full use of these motors:

# Motor temperature sensor to be mapped and added to code
# Design files for adaptor boards posted to github

[[Category:OEM]] [[Category:BMW]] [[Category:Inverter]]

BMW i3 Inverter

2024-04-27T18:49:07Z

CJW: Clarified wording

BMW I3 inverter
[[File:BMW I3 inverter.jpg|thumb|BMW I3 inverter]]

Forum thread: https://openinverter.org/forum/viewtopic.php?p=23214#p23214

BMW i3™ inverter drop-in board Available

https://openinverter.org/shop/index.php?route=product/product&product_id=72

'''<big>Overview</big>'''

There are 2 variants of the i3, the standard i3 with motor power rated at 125kW and the i3s rated at 135kW.

There are 2 subvariants, as REX versions have an additional 25kw inverter and onboard generator.

Power stage: [https://www.infineon.com/dgdl/Infineon-HybridPACK2_Power_Modules-PB-v01_00-EN.pdf?fileId=db3a3043353fdc16013557f17ce67b60 Infineon FS800R07] IGBTs rated for 800amps 650v

'''<big>Openinverter Drop-in Board</big>'''
[[File:Openinverter i3 drop-in board.jpg|thumb|300x300px|Openinverter i3 drop-in board]]
The drop-in board houses the openinverter, generates 32V for the gate driver board, communicates via SPI with the gate driver board to obtain voltage and temperature readouts, and provides outputs to operate contactors. See bottom of the page for list of modifications required for these boards to work. Pinouts for the three connectors on this board below.

{| class="wikitable"
|+ Pinout for Ampseal Plug
|-
! Pin No !! Assigniment !! Description
|-
| 1|| 12V ||
|-
| 2|| BRAKE_IN ||
|-
| 3|| PRECHARGE_OUT ||
|-
| 4|| CANL ||
|-
| 5|| CANH ||
|-
| 6|| DCSW_OUT ||
|-
| 7|| FORWARD_IN ||
|-
| 8|| REVERSE_IN ||
|-
| 9|| 5V (OUT) ||
|-
| 10|| RESOLVER_S2/ENCODER_A || Sin Hi
|-
| 11|| GND ||
|-
| 12|| RESOLVER_S1 || Sin Lo
|-
| 13|| THROTTLE1 ||
|-
| 14|| THROTTLE2 ||
|-
| 15|| RESOLVER_R1 || Ex Hi
|-
| 16|| RESOLVER_S3/ENCODER_B || Cos Hi
|-
| 17|| MTEMP+ ||
|-
| 18|| MTEMP- ||
|-
| 19|| RESOLVER_S4 || Cos Lo
|-
| 20|| EMCYSTOP_IN ||
|-
| 21 || GND ||
|-
| 22|| RESOLVER_R2 || Ex Lo
|-
| 23|| START_IN ||
|}

{| class="wikitable"
|+Pinout for Gate Driver Board
!Pin No
!I/O
!Description
!Notes
!
!Pin No
!I/O
!Description
!Notes
|-
|1
|
|
|
|
|21
|
|GND Switching Mosfets ?
|
|-
|2
|I
|32V in
|
|
|22
|
|GND Switching Mosfets ?
|
|-
|3
|I
|32V in
|
|
|23
|
|
|
|-
|4
|I
|IGBT A HI
|
|
|24
|
|
|
|-
|5
|I
|IGBT A LOW
|
|
|25
|
|
|
|-
|6
|I
|'''CS (ADC)'''
|
|
|26
|
|GND IGBT Driver ground
|
|-
|7
|I
|'''SDI'''
|
|
|27
|
|GND IGBT Driver ground
|
|-
|8
|I
|'''SDO'''
|
|
|28
|
|GND IGBT Driver ground
|
|-
|9
|I
|'''SCK'''
|
|
|29
|
|GND IGBT Driver ground
|
|-
|10
|I
|IGBT B HI
|
|
|30
|
|GND IGBT Driver ground
|
|-
|11
|I
|IGBT B LOW
|
|
|31
|
|GND IGBT Driver ground
|
|-
|12
|I
|IGBT C HI
|
|
|32
|
|GND IGBT Driver ground
|
|-
|13
|I
|IGBT C LOW
|
|
|33
|
|5V IGBT Driver Power
|
|-
|14
|
|
|
|
|34
|
|5V IGBT Driver Power
|
|-
|15
|
|
|
|
|35
|I
|IGBT PSU on (5V or 12V)
|
|-
|16
|O
|IGBT DRIVER UVW Upper Ready
|
|
|36
|O
|IGBT Driver Fault
|
|-
|17
|O
|IGBT DRIVER UVW Lower Ready
|
|
|37
|I
|5V LEM Current sensor Power
|
|-
|18
|O
|Current Sense C Signal
|
|
|38
|
|GND Current sensor Ground
|
|-
|19
|O
|Current Sense B Signal
|
|
|39
|
|GND Current sensor Ground
|
|-
|20
|O
|Current Sense A Signal
|
|
|40
|
|GND Current sensor Ground
|
|}

Note: Pin 35 is connected to a [https://openinverter.org/forum/viewtopic.php?p=69712#p69712 mosfet gate on the gate driver board] and has been tested with both 5V and 12V.

'''<big>Motor Resolver & Temperature Sensors</big>'''

12-pin PCB header to connect to the motor sensors is an ERNI MiniBridge, part number 294920

Wire colours to pin allocation below determined by schematic and multimeter trace, with resolver coils and temperature sensors checked for resistance. Confirmed with motor bench test. [[File:ERNI Minibridge Connector.jpg|thumb|ERNI Minibridge Connector. Dots indicate pin 1.]]
{| class="wikitable"
|+Pinout for ERNI Microbridge
!Pin No
!Colour
!Description
!Notes
|-
|1
|Brown
|Sin Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω.
|-
|2
|Blue
|Sin Lo
|-
|3
|Yellow
|Ex Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω
|-
|4
|Green
|Ex Lo
|-
|5
|Red
|Cos Hi
| rowspan="2" |Twisted pair. 13.6 - 20.4 Ω
|-
|6
|White
|Cos Lo
|-
|7
|Blue
| rowspan="2" |Temperature
Sensor
| rowspan="4" |From BMW Service Technical Training Manual - I01 High-voltage Components:
There are two stator coil temperature sensors.

The rotor temperature is determined using readings from the stator temperature sensors.
|-
|8
|Grey
|-
|9
|Red
| rowspan="2" |Temperature
Sensor
|-
|10
|Grey
|-
|11
| -
|Unused
| rowspan="2" |These wires terminate in one of the six pin connectors in the motor housing. There is nothing connected to them.
|-
|12
| -
|Unused
|}

[[File:Mod 1. - Close SJ3.jpg|thumb|Mod 1. Close SJ3]]

'''<big>Modifications required to drop-in boards</big>'''

Five modifications are required for the drop-in boards to work, plus an additional one if using CAN communication.

'''Mod''' '''1. Close SJ3 on the openinverter board with solder'''

This enables SPI communications by assigned Pin 4 on JP2 as the MOSI line. [[Mini Mainboard|Additional explanation here]].

'''Mod''' '''2. Motor Resolver & Temperature Sensor Adaptor Boards'''
[[File:Ampseal board.png|thumb|300x300px|Mod 2. - Ampseal adapter board]]
[[File:ERNI Microbridge adapter board.png|thumb|300x300px|Mod 2. - ERNI Microbridge adapter board]]
A [https://openinverter.org/forum/viewtopic.php?p=63903#p63903 pair of adaptor boards] (see also images to right) are available and shipped with the current drop-in boards. These enable the ERNI Microbridge connector from the resolver and motor temperature sensors to be connected to the required pins on the Ampseal connector. Design files for these boards will be posted on github at some point - if you need a copy in the meantime contact user 'CJW' or post on the i3 controller hacking thread.

'''Mod''' '''3.''' '''Code Update for Gate Driver Board - SPI Commication'''

The BMW i3 gate driver board communicates the DC bus voltage (ie traction battery voltage) and IGBT heatsink temperatures to the Openinverter via SPI.

On the Openinverter mini mainboard, pin 17 on JP2 is normally used as an 'Error Output'. When used with the BMW i3, this pin must instead be used for the SPI Clock signal.

To avoid the clock signal being pulled high or low by the pin acting as an Error Output, find this section of code in vehiclecontrol.cpp:<syntaxhighlight lang="cpp">
//Brake pin is used as SPI_MISO
DigIo::brk_out.Configure(GPIOC, GPIO5, PinMode::INPUT_FLT);

</syntaxhighlight>and insert these lines of code below it, to disable the Error Output:<syntaxhighlight lang="cpp">
//Disable err_out so it doesn't pull the clock signal up or down
DigIo::err_out.Configure(GPIOC, GPIO10, PinMode::INPUT_FLT);
</syntaxhighlight>

[[File:Mod 5. - Gate driver PSU.jpg|thumb|Mod 5. - Gate driver PSU power pin]]

'''Mod 4.''' '''Check solder connections on the drop-in board'''

The 40 pin surface mount Harwin connector to the gate driver board may have dry joints or shorts.

'''Mod 5.''' '''Gate driver PSU power pin'''

Pin 35 of the Harwin connector to the gate driver board is not connected to anything. Testing indicates this must be powered for the gate driver to work, at least on some boards. The motor has been run successfully with [https://openinverter.org/forum/viewtopic.php?p=70213#p70213 5V to this pin via a 10K resistor from the adjacent pin 34], which receives power from the openinverter's 5V supply. Some earlier notes in the i3 hacking thread suggest it may also have been tested with 12V.

'''Mod 6. CAN slew rate pin'''

This pin is floating but needs to be [https://openinverter.org/forum/viewtopic.php?p=41110#p41110 tied to ground with a resistor] if CAN communication is used. Can be any value from like 0R to 20k, the value controls the slew rate.

'''<big>Openinverter Parameters</big>'''

[https://openinverter.org/forum/viewtopic.php?p=69749#p69749 This initial set of parameters] have been used for successfull bench testing a motor with a pair of lead acid car batteries. Will update and eventually post a full set of parameters here once the motor is properly set up and has been tested with a high voltage battery.

'''<big>Future Development</big>'''

List of tasks to be completed to enable full use of these motors:

# Motor temperature sensor to be mapped and added to code
# Design files for adaptor boards posted to github

[[Category:OEM]] [[Category:BMW]] [[Category:Inverter]]

BMW i3 Inverter

2024-04-27T18:44:51Z

CJW:

BMW I3 inverter
[[File:BMW I3 inverter.jpg|thumb|BMW I3 inverter]]

Forum thread: https://openinverter.org/forum/viewtopic.php?p=23214#p23214

BMW i3™ inverter drop-in board Available

https://openinverter.org/shop/index.php?route=product/product&product_id=72

'''<big>Overview</big>'''

There are 2 variants of the i3, the standard i3 with motor power rated at 125kW and the i3s rated at 135kW.

There are 2 subvariants, as REX versions have an additional 25kw inverter and onboard generator.

Power stage: [https://www.infineon.com/dgdl/Infineon-HybridPACK2_Power_Modules-PB-v01_00-EN.pdf?fileId=db3a3043353fdc16013557f17ce67b60 Infineon FS800R07] IGBTs rated for 800amps 650v

'''<big>Openinverter Drop-in Board</big>'''
[[File:Openinverter i3 drop-in board.jpg|thumb|300x300px|Openinverter i3 drop-in board]]
The drop-in board houses the openinverter, generates 32V for the gate driver board, communicates via SPI with the gate driver board to obtain voltage and temperature readouts, and provides outputs to operate contactors. See bottom of the page for list of modifications required for these boards to work. Pinouts for the three connectors on this board below.

{| class="wikitable"
|+ Pinout for Ampseal Plug
|-
! Pin No !! Assigniment !! Description
|-
| 1|| 12V ||
|-
| 2|| BRAKE_IN ||
|-
| 3|| PRECHARGE_OUT ||
|-
| 4|| CANL ||
|-
| 5|| CANH ||
|-
| 6|| DCSW_OUT ||
|-
| 7|| FORWARD_IN ||
|-
| 8|| REVERSE_IN ||
|-
| 9|| 5V (OUT) ||
|-
| 10|| RESOLVER_S2/ENCODER_A || Sin Hi
|-
| 11|| GND ||
|-
| 12|| RESOLVER_S1 || Sin Lo
|-
| 13|| THROTTLE1 ||
|-
| 14|| THROTTLE2 ||
|-
| 15|| RESOLVER_R1 || Ex Hi
|-
| 16|| RESOLVER_S3/ENCODER_B || Cos Hi
|-
| 17|| MTEMP+ ||
|-
| 18|| MTEMP- ||
|-
| 19|| RESOLVER_S4 || Cos Lo
|-
| 20|| EMCYSTOP_IN ||
|-
| 21 || GND ||
|-
| 22|| RESOLVER_R2 || Ex Lo
|-
| 23|| START_IN ||
|}

{| class="wikitable"
|+Pinout for Gate Driver Board
!Pin No
!I/O
!Description
!Notes
!
!Pin No
!I/O
!Description
!Notes
|-
|1
|
|
|
|
|21
|
|GND Switching Mosfets ?
|
|-
|2
|I
|32V in
|
|
|22
|
|GND Switching Mosfets ?
|
|-
|3
|I
|32V in
|
|
|23
|
|
|
|-
|4
|I
|IGBT A HI
|
|
|24
|
|
|
|-
|5
|I
|IGBT A LOW
|
|
|25
|
|
|
|-
|6
|I
|'''CS (ADC)'''
|
|
|26
|
|GND IGBT Driver ground
|
|-
|7
|I
|'''SDI'''
|
|
|27
|
|GND IGBT Driver ground
|
|-
|8
|I
|'''SDO'''
|
|
|28
|
|GND IGBT Driver ground
|
|-
|9
|I
|'''SCK'''
|
|
|29
|
|GND IGBT Driver ground
|
|-
|10
|I
|IGBT B HI
|
|
|30
|
|GND IGBT Driver ground
|
|-
|11
|I
|IGBT B LOW
|
|
|31
|
|GND IGBT Driver ground
|
|-
|12
|I
|IGBT C HI
|
|
|32
|
|GND IGBT Driver ground
|
|-
|13
|I
|IGBT C LOW
|
|
|33
|
|5V IGBT Driver Power
|
|-
|14
|
|
|
|
|34
|
|5V IGBT Driver Power
|
|-
|15
|
|
|
|
|35
|I
|IGBT PSU on (5V or 12V)
|
|-
|16
|O
|IGBT DRIVER UVW Upper Ready
|
|
|36
|O
|IGBT Driver Fault
|
|-
|17
|O
|IGBT DRIVER UVW Lower Ready
|
|
|37
|I
|5V LEM Current sensor Power
|
|-
|18
|O
|Current Sense C Signal
|
|
|38
|
|GND Current sensor Ground
|
|-
|19
|O
|Current Sense B Signal
|
|
|39
|
|GND Current sensor Ground
|
|-
|20
|O
|Current Sense A Signal
|
|
|40
|
|GND Current sensor Ground
|
|}

Note: Pin 35 is connected to a [https://openinverter.org/forum/viewtopic.php?p=69712#p69712 mosfet gate on the gate driver board] and has been tested with both 5V and 12V.

'''<big>Motor Resolver & Temperature Sensors</big>'''

12-pin PCB header to connect to the motor sensors is an ERNI MiniBridge, part number 294920

Wire colours to pin allocation below determined by schematic and multimeter trace, with resolver coils and temperature sensors checked for resistance. Confirmed with motor bench test. [[File:ERNI Minibridge Connector.jpg|thumb|ERNI Minibridge Connector. Dots indicate pin 1.]]
{| class="wikitable"
|+Pinout for ERNI Microbridge
!Pin No
!Colour
!Description
!Notes
|-
|1
|Brown
|Sin Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω.
|-
|2
|Blue
|Sin Lo
|-
|3
|Yellow
|Ex Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω
|-
|4
|Green
|Ex Lo
|-
|5
|Red
|Cos Hi
| rowspan="2" |Twisted pair. 13.6 - 20.4 Ω
|-
|6
|White
|Cos Lo
|-
|7
|Blue
| rowspan="2" |Temperature
Sensor
| rowspan="4" |From BMW Service Technical Training Manual - I01 High-voltage Components:
There are two stator coil temperature sensors.

The rotor temperature is determined using readings from the stator temperature sensors.
|-
|8
|Grey
|-
|9
|Red
| rowspan="2" |Temperature
Sensor
|-
|10
|Grey
|-
|11
| -
|Unused
| rowspan="2" |These wires terminate in one of the six pin connectors in the motor housing. There is nothing connected to them.
|-
|12
| -
|Unused
|}

[[File:Mod 1. - Close SJ3.jpg|thumb|Mod 1. Close SJ3]]

'''<big>Modifications required to drop-in boards</big>'''

Five modifications are required for the drop-in boards to work, plus an additional one if using CAN communication.

'''Mod''' '''1. Close SJ3 on the openinverter board with solder'''

This enables SPI communications by assigned Pin 4 on JP2 as the MOSI line. [[Mini Mainboard|Additional explanation here]].

'''Mod''' '''2. Motor Resolver & Temperature Sensor Adaptor Boards'''
[[File:Ampseal board.png|thumb|300x300px|Mod 2. - Ampseal adapter board]]
[[File:ERNI Microbridge adapter board.png|thumb|300x300px|Mod 2. - ERNI Microbridge adapter board]]
A [https://openinverter.org/forum/viewtopic.php?p=63903#p63903 pair of adaptor boards] (see also images to right) are available and shipped with the current drop-in boards. These enable the ERNI Microbridge connector from the resolver and motor temperature sensors to be connected to the required pins on the Ampseal connector. Design files for these boards will be posted on github at some point - if you need a copy in the meantime contact user 'CJW' or post on the i3 controller hacking thread.

'''Mod''' '''3.''' '''Code Update for Gate Driver Board - SPI Commication'''

The BMW i3 gate driver board communicates the DC bus voltage (ie traction battery voltage) and IGBT heatsink temperatures to the Openinverter via SPI.

On the Openinverter mini mainboard, pin 17 on JP2 is normally used as an 'Error Output'. When used with the BMW i3, this pin must instead be used for the SPI Clock signal.

To avoid the clock signal being pulled high or low by the pin acting as an Error Output, find this section of code in vehiclecontrol.cpp:<syntaxhighlight lang="cpp">
//Brake pin is used as SPI_MISO
DigIo::brk_out.Configure(GPIOC, GPIO5, PinMode::INPUT_FLT);

</syntaxhighlight>and insert these lines of code below it, to disable the Error Output:<syntaxhighlight lang="cpp">
//Disable err_out so it doesn't pull the clock signal up or down
DigIo::err_out.Configure(GPIOC, GPIO10, PinMode::INPUT_FLT);
</syntaxhighlight>

[[File:Mod 5. - Gate driver PSU.jpg|thumb|Mod 5. - Gate driver PSU]]

'''Mod 4.''' '''Check solder connections on the drop-in board'''

The 40 pin surface mount Harwin connector to the gate driver board may have dry joints or shorts.

'''Mod 5.''' '''Gate driver PSU on pin'''

Pin 35 of the Harwin connector to the gate driver board is not connected to anything. Testing indicates this must be powered for the gate driver to work, at least on some boards. The motor has been run successfully with [https://openinverter.org/forum/viewtopic.php?p=70213#p70213 5V to this pin via a 10K resistor from the adjacent pin 34], which receives power from the openinverter's 5V supply.

'''Mod 6. CAN slew rate pin'''

This pin is floating but needs to be [https://openinverter.org/forum/viewtopic.php?p=41110#p41110 tied to ground with a resistor] if CAN communication is used. Can be any value from like 0R to 20k, the value controls the slew rate.

'''<big>Openinverter Parameters</big>'''

[https://openinverter.org/forum/viewtopic.php?p=69749#p69749 This initial set of parameters] have been used for successfull bench testing a motor with a pair of lead acid car batteries. Will update and eventually post a full set of parameters here once the motor is properly set up and has been tested with a high voltage battery.

'''<big>Future Development</big>'''

List of tasks to be completed to enable full use of these motors:

# Motor temperature sensor to be mapped and added to code
# Design files for adaptor boards posted to github

[[Category:OEM]] [[Category:BMW]] [[Category:Inverter]]

BMW i3 Inverter

2024-04-27T18:38:33Z

CJW:

BMW I3 inverter
[[File:BMW I3 inverter.jpg|thumb|BMW I3 inverter]]

Forum thread: https://openinverter.org/forum/viewtopic.php?p=23214#p23214

BMW i3™ inverter drop-in board Available

https://openinverter.org/shop/index.php?route=product/product&product_id=72

'''<big>Overview</big>'''

There are 2 variants of the i3, the standard i3 with motor power rated at 125kW and the i3s rated at 135kW.

There are 2 subvariants, as REX versions have an additional 25kw inverter and onboard generator.

Power stage: [https://www.infineon.com/dgdl/Infineon-HybridPACK2_Power_Modules-PB-v01_00-EN.pdf?fileId=db3a3043353fdc16013557f17ce67b60 Infineon FS800R07] IGBTs rated for 800amps 650v

'''<big>Openinverter Drop-in Board</big>'''
[[File:Openinverter i3 drop-in board.jpg|thumb|300x300px|Openinverter i3 drop-in board]]
The drop-in board houses the openinverter, generates 32V for the gate driver board, communicates via SPI with the gate driver board to obtain voltage and temperature readouts, and provides outputs to operate contactors. See bottom of the page for list of modifications required for these boards to work. Pinouts for the three connectors on this board below.

{| class="wikitable"
|+ Pinout for Ampseal Plug
|-
! Pin No !! Assigniment !! Description
|-
| 1|| 12V ||
|-
| 2|| BRAKE_IN ||
|-
| 3|| PRECHARGE_OUT ||
|-
| 4|| CANL ||
|-
| 5|| CANH ||
|-
| 6|| DCSW_OUT ||
|-
| 7|| FORWARD_IN ||
|-
| 8|| REVERSE_IN ||
|-
| 9|| 5V (OUT) ||
|-
| 10|| RESOLVER_S2/ENCODER_A || Sin Hi
|-
| 11|| GND ||
|-
| 12|| RESOLVER_S1 || Sin Lo
|-
| 13|| THROTTLE1 ||
|-
| 14|| THROTTLE2 ||
|-
| 15|| RESOLVER_R1 || Ex Hi
|-
| 16|| RESOLVER_S3/ENCODER_B || Cos Hi
|-
| 17|| MTEMP+ ||
|-
| 18|| MTEMP- ||
|-
| 19|| RESOLVER_S4 || Cos Lo
|-
| 20|| EMCYSTOP_IN ||
|-
| 21 || GND ||
|-
| 22|| RESOLVER_R2 || Ex Lo
|-
| 23|| START_IN ||
|}

{| class="wikitable"
|+Pinout for Gate Driver Board
!Pin No
!I/O
!Description
!Notes
!
!Pin No
!I/O
!Description
!Notes
|-
|1
|
|
|
|
|21
|
|GND Switching Mosfets ?
|
|-
|2
|I
|32V in
|
|
|22
|
|GND Switching Mosfets ?
|
|-
|3
|I
|32V in
|
|
|23
|
|
|
|-
|4
|I
|IGBT A HI
|
|
|24
|
|
|
|-
|5
|I
|IGBT A LOW
|
|
|25
|
|
|
|-
|6
|I
|'''CS (ADC)'''
|
|
|26
|
|GND IGBT Driver ground
|
|-
|7
|I
|'''SDI'''
|
|
|27
|
|GND IGBT Driver ground
|
|-
|8
|I
|'''SDO'''
|
|
|28
|
|GND IGBT Driver ground
|
|-
|9
|I
|'''SCK'''
|
|
|29
|
|GND IGBT Driver ground
|
|-
|10
|I
|IGBT B HI
|
|
|30
|
|GND IGBT Driver ground
|
|-
|11
|I
|IGBT B LOW
|
|
|31
|
|GND IGBT Driver ground
|
|-
|12
|I
|IGBT C HI
|
|
|32
|
|GND IGBT Driver ground
|
|-
|13
|I
|IGBT C LOW
|
|
|33
|
|5V IGBT Driver Power
|
|-
|14
|
|
|
|
|34
|
|5V IGBT Driver Power
|
|-
|15
|
|
|
|
|35
|I
|IGBT PSU on (5V or 12V)
|
|-
|16
|O
|IGBT DRIVER UVW Upper Ready
|
|
|36
|O
|IGBT Driver Fault
|
|-
|17
|O
|IGBT DRIVER UVW Lower Ready
|
|
|37
|I
|5V LEM Current sensor Power
|
|-
|18
|O
|Current Sense C Signal
|
|
|38
|
|GND Current sensor Ground
|
|-
|19
|O
|Current Sense B Signal
|
|
|39
|
|GND Current sensor Ground
|
|-
|20
|O
|Current Sense A Signal
|
|
|40
|
|GND Current sensor Ground
|
|}

Note: Pin 35 is connected to a [https://openinverter.org/forum/viewtopic.php?p=69712#p69712 mosfet gate on the gate driver board] and has been tested with both 5V and 12V.
'''<big>Motor Resolver & Temperature Sensors</big>'''

'''<big>Motor Resolver & Temperature Sensors</big>'''

12-pin PCB header to connect to the motor sensors is an ERNI MiniBridge, part number 294920

Wire colours to pin allocation below determined by schematic and multimeter trace, with resolver coils and temperature sensors checked for resistance. Confirmed with motor bench test. [[File:ERNI Minibridge Connector.jpg|thumb|ERNI Minibridge Connector. Dots indicate pin 1.]]
{| class="wikitable"
|+Pinout for ERNI Microbridge
!Pin No
!Colour
!Description
!Notes
|-
|1
|Brown
|Sin Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω.
|-
|2
|Blue
|Sin Lo
|-
|3
|Yellow
|Ex Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω
|-
|4
|Green
|Ex Lo
|-
|5
|Red
|Cos Hi
| rowspan="2" |Twisted pair. 13.6 - 20.4 Ω
|-
|6
|White
|Cos Lo
|-
|7
|Blue
| rowspan="2" |Temperature
Sensor
| rowspan="4" |From BMW Service Technical Training Manual - I01 High-voltage Components:
There are two stator coil temperature sensors.

The rotor temperature is determined using readings from the stator temperature sensors.
|-
|8
|Grey
|-
|9
|Red
| rowspan="2" |Temperature
Sensor
|-
|10
|Grey
|-
|11
| -
|Unused
| rowspan="2" |These wires terminate in one of the six pin connectors in the motor housing. There is nothing connected to them.
|-
|12
| -
|Unused
|}

[[File:Mod 1. - Close SJ3.jpg|thumb|Mod 1. Close SJ3]]
'''<big>Modifications required to drop-in boards</big>'''

Five modifications are required for the drop-in boards to work, plus an additional one if using CAN communication.

'''Mod''' '''1. Close SJ3 on the openinverter board with solder'''

This enables SPI communications by assigned Pin 4 on JP2 as the MOSI line. [[Mini Mainboard|Additional explanation here]].

'''Mod''' '''2. Motor Resolver & Temperature Sensor Adaptor Boards'''
[[File:Ampseal board.png|thumb|300x300px|Mod 2. - Ampseal adapter board]]
[[File:ERNI Microbridge adapter board.png|thumb|300x300px|Mod 2. - ERNI Microbridge adapter board]]
A [https://openinverter.org/forum/viewtopic.php?p=63903#p63903 pair of adaptor boards] (see also images to right) are available and shipped with the current drop-in boards. These enable the ERNI Microbridge connector from the resolver and motor temperature sensors to be connected to the required pins on the Ampseal connector. Design files for these boards will be posted on github at some point - if you need a copy in the meantime contact user 'CJW' or post on the i3 controller hacking thread.

'''Mod''' '''3.''' '''Code Update for Gate Driver Board - SPI Commication'''

The BMW i3 gate driver board communicates the DC bus voltage (ie traction battery voltage) and IGBT heatsink temperatures to the Openinverter via SPI.

On the Openinverter mini mainboard, pin 17 on JP2 is normally used as an 'Error Output'. When used with the BMW i3, this pin must instead be used for the SPI Clock signal.

To avoid the clock signal being pulled high or low by the pin acting as an Error Output, find this section of code in vehiclecontrol.cpp:<syntaxhighlight lang="cpp">
//Brake pin is used as SPI_MISO
DigIo::brk_out.Configure(GPIOC, GPIO5, PinMode::INPUT_FLT);

</syntaxhighlight>and insert these lines of code below it, to disable the Error Output:<syntaxhighlight lang="cpp">
//Disable err_out so it doesn't pull the clock signal up or down
DigIo::err_out.Configure(GPIOC, GPIO10, PinMode::INPUT_FLT);
</syntaxhighlight>

[[File:Mod 5. - Gate driver PSU.jpg|thumb|Mod 5. - Gate driver PSU]]
'''Mod 4.''' '''Check solder connections on the drop-in board'''

The 40 pin surface mount Harwin connector to the gate driver board may have dry joints or shorts.
'''Mod 5.''' '''Gate driver PSU on pin'''

'''Mod 5.''' '''Gate driver PSU on pin'''

Pin 35 of the Harwin connector to the gate driver board is not connected to anything. Testing indicates this must be powered for the gate driver to work, at least on some boards. The motor has been run successfully with [https://openinverter.org/forum/viewtopic.php?p=70213#p70213 5V to this pin via a 10K resistor from the adjacent pin 34], which receives power from the openinverter's 5V supply.
'''Mod 6. CAN slew rate pin'''

'''Mod 6. CAN slew rate pin'''

This pin is floating but needs to be [https://openinverter.org/forum/viewtopic.php?p=41110#p41110 tied to ground with a resistor] if CAN communication is used. Can be any value from like 0R to 20k, the value controls the slew rate.

'''<big>Openinverter Parameters</big>'''

[https://openinverter.org/forum/viewtopic.php?p=69749#p69749 This initial set of parameters] have been used for successfull bench testing a motor with a pair of lead acid car batteries. Will update and eventually post a full set of parameters here once the motor is properly set up and has been tested with a high voltage battery.

'''<big>Future Development</big>'''

List of tasks to be completed to enable full use of these motors:

# Motor temperature sensor to be mapped and added to code
# Design files for adaptor boards posted to github

[[Category:OEM]] [[Category:BMW]] [[Category:Inverter]]

BMW i3 Inverter

2024-04-27T18:37:19Z

CJW: Consolidated list of modifications required to drop-in board and added more photos and links

BMW I3 inverter
[[File:BMW I3 inverter.jpg|thumb|BMW I3 inverter]]

Forum thread: https://openinverter.org/forum/viewtopic.php?p=23214#p23214

BMW i3™ inverter drop-in board Available

https://openinverter.org/shop/index.php?route=product/product&product_id=72

'''<big>Overview</big>'''

There are 2 variants of the i3, the standard i3 with motor power rated at 125kW and the i3s rated at 135kW.

There are 2 subvariants, as REX versions have an additional 25kw inverter and onboard generator.

Power stage: [https://www.infineon.com/dgdl/Infineon-HybridPACK2_Power_Modules-PB-v01_00-EN.pdf?fileId=db3a3043353fdc16013557f17ce67b60 Infineon FS800R07] IGBTs rated for 800amps 650v

'''<big>Openinverter Drop-in Board</big>'''
[[File:Openinverter i3 drop-in board.jpg|thumb|300x300px|Openinverter i3 drop-in board]]
The drop-in board houses the openinverter, generates 32V for the gate driver board, communicates via SPI with the gate driver board to obtain voltage and temperature readouts, and provides outputs to operate contactors. See bottom of the page for list of modifications required for these boards to work. Pinouts for the three connectors on this board below.

{| class="wikitable"
|+ Pinout for Ampseal Plug
|-
! Pin No !! Assigniment !! Description
|-
| 1|| 12V ||
|-
| 2|| BRAKE_IN ||
|-
| 3|| PRECHARGE_OUT ||
|-
| 4|| CANL ||
|-
| 5|| CANH ||
|-
| 6|| DCSW_OUT ||
|-
| 7|| FORWARD_IN ||
|-
| 8|| REVERSE_IN ||
|-
| 9|| 5V (OUT) ||
|-
| 10|| RESOLVER_S2/ENCODER_A || Sin Hi
|-
| 11|| GND ||
|-
| 12|| RESOLVER_S1 || Sin Lo
|-
| 13|| THROTTLE1 ||
|-
| 14|| THROTTLE2 ||
|-
| 15|| RESOLVER_R1 || Ex Hi
|-
| 16|| RESOLVER_S3/ENCODER_B || Cos Hi
|-
| 17|| MTEMP+ ||
|-
| 18|| MTEMP- ||
|-
| 19|| RESOLVER_S4 || Cos Lo
|-
| 20|| EMCYSTOP_IN ||
|-
| 21 || GND ||
|-
| 22|| RESOLVER_R2 || Ex Lo
|-
| 23|| START_IN ||
|}

{| class="wikitable"
|+Pinout for Gate Driver Board
!Pin No
!I/O
!Description
!Notes
!
!Pin No
!I/O
!Description
!Notes
|-
|1
|
|
|
|
|21
|
|GND Switching Mosfets ?
|
|-
|2
|I
|32V in
|
|
|22
|
|GND Switching Mosfets ?
|
|-
|3
|I
|32V in
|
|
|23
|
|
|
|-
|4
|I
|IGBT A HI
|
|
|24
|
|
|
|-
|5
|I
|IGBT A LOW
|
|
|25
|
|
|
|-
|6
|I
|'''CS (ADC)'''
|
|
|26
|
|GND IGBT Driver ground
|
|-
|7
|I
|'''SDI'''
|
|
|27
|
|GND IGBT Driver ground
|
|-
|8
|I
|'''SDO'''
|
|
|28
|
|GND IGBT Driver ground
|
|-
|9
|I
|'''SCK'''
|
|
|29
|
|GND IGBT Driver ground
|
|-
|10
|I
|IGBT B HI
|
|
|30
|
|GND IGBT Driver ground
|
|-
|11
|I
|IGBT B LOW
|
|
|31
|
|GND IGBT Driver ground
|
|-
|12
|I
|IGBT C HI
|
|
|32
|
|GND IGBT Driver ground
|
|-
|13
|I
|IGBT C LOW
|
|
|33
|
|5V IGBT Driver Power
|
|-
|14
|
|
|
|
|34
|
|5V IGBT Driver Power
|
|-
|15
|
|
|
|
|35
|I
|IGBT PSU on (5V or 12V)
|
|-
|16
|O
|IGBT DRIVER UVW Upper Ready
|
|
|36
|O
|IGBT Driver Fault
|
|-
|17
|O
|IGBT DRIVER UVW Lower Ready
|
|
|37
|I
|5V LEM Current sensor Power
|
|-
|18
|O
|Current Sense C Signal
|
|
|38
|
|GND Current sensor Ground
|
|-
|19
|O
|Current Sense B Signal
|
|
|39
|
|GND Current sensor Ground
|
|-
|20
|O
|Current Sense A Signal
|
|
|40
|
|GND Current sensor Ground
|
|}

Note: Pin 35 is connected to a [https://openinverter.org/forum/viewtopic.php?p=69712#p69712 mosfet gate on the gate driver board] and has been tested with both 5V and 12V.

'''<big>Motor Resolver & Temperature Sensors</big>'''

12-pin PCB header to connect to the motor sensors is an ERNI MiniBridge, part number 294920

Wire colours to pin allocation below determined by schematic and multimeter trace, with resolver coils and temperature sensors checked for resistance. Confirmed with motor bench test. [[File:ERNI Minibridge Connector.jpg|thumb|ERNI Minibridge Connector. Dots indicate pin 1.]]
{| class="wikitable"
|+Pinout for ERNI Microbridge
!Pin No
!Colour
!Description
!Notes
|-
|1
|Brown
|Sin Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω.
|-
|2
|Blue
|Sin Lo
|-
|3
|Yellow
|Ex Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω
|-
|4
|Green
|Ex Lo
|-
|5
|Red
|Cos Hi
| rowspan="2" |Twisted pair. 13.6 - 20.4 Ω
|-
|6
|White
|Cos Lo
|-
|7
|Blue
| rowspan="2" |Temperature
Sensor
| rowspan="4" |From BMW Service Technical Training Manual - I01 High-voltage Components:
There are two stator coil temperature sensors.

The rotor temperature is determined using readings from the stator temperature sensors.
|-
|8
|Grey
|-
|9
|Red
| rowspan="2" |Temperature
Sensor
|-
|10
|Grey
|-
|11
| -
|Unused
| rowspan="2" |These wires terminate in one of the six pin connectors in the motor housing. There is nothing connected to them.
|-
|12
| -
|Unused
|}

[[File:Mod 1. - Close SJ3.jpg|thumb|Mod 1. Close SJ3]]
'''<big>Modifications required to drop-in boards</big>'''

Five modifications are required for the drop-in boards to work, plus an additional one if using CAN communication.

'''Mod''' '''1. Close SJ3 on the openinverter board with solder'''

This enables SPI communications by assigned Pin 4 on JP2 as the MOSI line. [[Mini Mainboard|Additional explanation here]].

'''Mod''' '''2. Motor Resolver & Temperature Sensor Adaptor Boards'''
[[File:Ampseal board.png|thumb|300x300px|Mod 2. - Ampseal adapter board]]
[[File:ERNI Microbridge adapter board.png|thumb|300x300px|Mod 2. - ERNI Microbridge adapter board]]
A [https://openinverter.org/forum/viewtopic.php?p=63903#p63903 pair of adaptor boards] (see also images to right) are available and shipped with the current drop-in boards. These enable the ERNI Microbridge connector from the resolver and motor temperature sensors to be connected to the required pins on the Ampseal connector. Design files for these boards will be posted on github at some point - if you need a copy in the meantime contact user 'CJW' or post on the i3 controller hacking thread.

'''Mod''' '''3.''' '''Code Update for Gate Driver Board - SPI Commication'''

The BMW i3 gate driver board communicates the DC bus voltage (ie traction battery voltage) and IGBT heatsink temperatures to the Openinverter via SPI.

On the Openinverter mini mainboard, pin 17 on JP2 is normally used as an 'Error Output'. When used with the BMW i3, this pin must instead be used for the SPI Clock signal.

To avoid the clock signal being pulled high or low by the pin acting as an Error Output, find this section of code in vehiclecontrol.cpp:<syntaxhighlight lang="cpp">
//Brake pin is used as SPI_MISO
DigIo::brk_out.Configure(GPIOC, GPIO5, PinMode::INPUT_FLT);

</syntaxhighlight>and insert these lines of code below it, to disable the Error Output:<syntaxhighlight lang="cpp">
//Disable err_out so it doesn't pull the clock signal up or down
DigIo::err_out.Configure(GPIOC, GPIO10, PinMode::INPUT_FLT);
</syntaxhighlight>

[[File:Mod 5. - Gate driver PSU.jpg|thumb|Mod 5. - Gate driver PSU]]
'''Mod 4.''' '''Check solder connections on the drop-in board'''

The 40 pin surface mount Harwin connector to the gate driver board may have dry joints or shorts.

'''Mod 5.''' '''Gate driver PSU on pin'''

Pin 35 of the Harwin connector to the gate driver board is not connected to anything. Testing indicates this must be powered for the gate driver to work, at least on some boards. The motor has been run successfully with [https://openinverter.org/forum/viewtopic.php?p=70213#p70213 5V to this pin via a 10K resistor from the adjacent pin 34], which receives power from the openinverter's 5V supply.

'''Mod 6. CAN slew rate pin'''

This pin is floating but needs to be [https://openinverter.org/forum/viewtopic.php?p=41110#p41110 tied to ground with a resistor] if CAN communication is used. Can be any value from like 0R to 20k, the value controls the slew rate.

'''<big>Openinverter Parameters</big>'''

[https://openinverter.org/forum/viewtopic.php?p=69749#p69749 This initial set of parameters] have been used for successfull bench testing a motor with a pair of lead acid car batteries. Will update and eventually post a full set of parameters here once the motor is properly set up and has been tested with a high voltage battery.

'''<big>Future Development</big>'''

List of tasks to be completed to enable full use of these motors:

# Motor temperature sensor to be mapped and added to code
# Design files for adaptor boards posted to github

[[Category:OEM]] [[Category:BMW]] [[Category:Inverter]]

File:Mod 1. - Close SJ3.jpg

2024-04-27T18:34:48Z

CJW:

Mod 1. - Close SJ3

File:Mod 1. Close SJ3.jpg

2024-04-27T18:32:21Z

CJW:

Mod 1. Close SJ3

File:Mod 5. - Gate driver PSU.jpg

2024-04-27T18:26:17Z

CJW:

Mod 5. - Gate driver PSU

BMW i3 Inverter

2024-04-27T17:56:10Z

CJW: Clarified mod required to pin 35 on Harwin connector. Added links to i3 controller hacking thread for more info on mods required.

BMW I3 inverter
[[File:BMW I3 inverter.jpg|thumb|BMW I3 inverter]]

Forum thread: https://openinverter.org/forum/viewtopic.php?p=23214#p23214

BMW i3™ inverter drop-in board Available

https://openinverter.org/shop/index.php?route=product/product&product_id=72

'''Overview'''

There are 2 variants of the i3, the standard i3 with motor power rated at 125kW and the i3s rated at 135kW.

There are 2 subvariants, as REX versions have an additional 25kw inverter and onboard generator.

Power stage: [https://www.infineon.com/dgdl/Infineon-HybridPACK2_Power_Modules-PB-v01_00-EN.pdf?fileId=db3a3043353fdc16013557f17ce67b60 Infineon FS800R07] IGBTs rated for 800amps 650v

'''Openinverter Drop-in Board'''
[[File:Openinverter i3 drop-in board.jpg|thumb|300x300px|Openinverter i3 drop-in board]]
The drop-in board houses the openinverter, generates 32V for the gate driver board, communicates via SPI with the gate driver board to obtain voltage and temperature readouts, and provides outputs to operate contactors.

As of 18 April 2024, the following mods are required to use these boards:

# Motor resolver and temperature sensor connector needs to be linked to the correct ampseal pins ([https://openinverter.org/forum/viewtopic.php?p=63903#p63903 this can be done with an additional pair of PCBs])
# Check solder connections on the 40 pin surface mount Harwin connector to the gate driver board for dry joints or shorts
# Apply code update in section below to prevent err_out pin on openinverter interfering with SPI communications
# Pin 35 of the Harwin connector to the gate driver board is not connected to anything. Testing indicates this must be powered for the gate driver to work, at least on some boards. The motor has been run successfully with [https://openinverter.org/forum/viewtopic.php?p=70213#p70213 5V to this pin via a 10K resistor from the adjacent pin 34], which receives power from the openinverter's 5V supply.

Pinouts for the three connectors on this board below.

{| class="wikitable"
|+ Pinout for Ampseal Plug
|-
! Pin No !! Assigniment !! Description
|-
| 1|| 12V ||
|-
| 2|| BRAKE_IN ||
|-
| 3|| PRECHARGE_OUT ||
|-
| 4|| CANL ||
|-
| 5|| CANH ||
|-
| 6|| DCSW_OUT ||
|-
| 7|| FORWARD_IN ||
|-
| 8|| REVERSE_IN ||
|-
| 9|| 5V (OUT) ||
|-
| 10|| RESOLVER_S2/ENCODER_A || Sin Hi
|-
| 11|| GND ||
|-
| 12|| RESOLVER_S1 || Sin Lo
|-
| 13|| THROTTLE1 ||
|-
| 14|| THROTTLE2 ||
|-
| 15|| RESOLVER_R1 || Ex Hi
|-
| 16|| RESOLVER_S3/ENCODER_B || Cos Hi
|-
| 17|| MTEMP+ ||
|-
| 18|| MTEMP- ||
|-
| 19|| RESOLVER_S4 || Cos Lo
|-
| 20|| EMCYSTOP_IN ||
|-
| 21 || GND ||
|-
| 22|| RESOLVER_R2 || Ex Lo
|-
| 23|| START_IN ||
|}

{| class="wikitable"
|+Pinout for Gate Driver Board
!Pin No
!I/O
!Description
!Notes
!
!Pin No
!I/O
!Description
!Notes
|-
|1
|
|
|
|
|21
|
|GND Switching Mosfets ?
|
|-
|2
|I
|32V in
|
|
|22
|
|GND Switching Mosfets ?
|
|-
|3
|I
|32V in
|
|
|23
|
|
|
|-
|4
|I
|IGBT A HI
|
|
|24
|
|
|
|-
|5
|I
|IGBT A LOW
|
|
|25
|
|
|
|-
|6
|I
|'''CS (ADC)'''
|
|
|26
|
|GND IGBT Driver ground
|
|-
|7
|I
|'''SDI'''
|
|
|27
|
|GND IGBT Driver ground
|
|-
|8
|I
|'''SDO'''
|
|
|28
|
|GND IGBT Driver ground
|
|-
|9
|I
|'''SCK'''
|
|
|29
|
|GND IGBT Driver ground
|
|-
|10
|I
|IGBT B HI
|
|
|30
|
|GND IGBT Driver ground
|
|-
|11
|I
|IGBT B LOW
|
|
|31
|
|GND IGBT Driver ground
|
|-
|12
|I
|IGBT C HI
|
|
|32
|
|GND IGBT Driver ground
|
|-
|13
|I
|IGBT C LOW
|
|
|33
|
|5V IGBT Driver Power
|
|-
|14
|
|
|
|
|34
|
|5V IGBT Driver Power
|
|-
|15
|
|
|
|
|35
|I
|IGBT PSU 12V on
|
|-
|16
|O
|IGBT DRIVER UVW Upper Ready
|
|
|36
|O
|IGBT Driver Fault
|
|-
|17
|O
|IGBT DRIVER UVW Lower Ready
|
|
|37
|I
|5V LEM Current sensor Power
|
|-
|18
|O
|Current Sense C Signal
|
|
|38
|
|GND Current sensor Ground
|
|-
|19
|O
|Current Sense B Signal
|
|
|39
|
|GND Current sensor Ground
|
|-
|20
|O
|Current Sense A Signal
|
|
|40
|
|GND Current sensor Ground
|
|}

'''Motor Resolver & Temperature Sensors'''

12-pin PCB header to connect to the motor sensors is an ERNI MiniBridge, part number 294920

Wire colours to pin allocation below determined by schematic and multimeter trace, with resolver coils and temperature sensors checked for resistance. Confirmed with motor bench test. [[File:ERNI Minibridge Connector.jpg|thumb|ERNI Minibridge Connector. Dots indicate pin 1.]]
{| class="wikitable"
|+Pinout for ERNI Microbridge
!Pin No
!Colour
!Description
!Notes
|-
|1
|Brown
|Sin Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω.
|-
|2
|Blue
|Sin Lo
|-
|3
|Yellow
|Ex Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω
|-
|4
|Green
|Ex Lo
|-
|5
|Red
|Cos Hi
| rowspan="2" |Twisted pair. 13.6 - 20.4 Ω
|-
|6
|White
|Cos Lo
|-
|7
|Blue
| rowspan="2" |Temperature
Sensor
| rowspan="4" |From BMW Service Technical Training Manual - I01 High-voltage Components:
There are two stator coil temperature sensors.

The rotor temperature is determined using readings from the stator temperature sensors.
|-
|8
|Grey
|-
|9
|Red
| rowspan="2" |Temperature
Sensor
|-
|10
|Grey
|-
|11
| -
|Unused
| rowspan="2" |These wires terminate in one of the six pin connectors in the motor housing. There is nothing connected to them.
|-
|12
| -
|Unused
|}

'''Motor Resolver & Temperature Sensor Adaptor Boards'''
[[File:ERNI Microbridge adapter board.png|thumb|300x300px|ERNI Microbridge adapter board]]
[[File:Ampseal board.png|thumb|300x300px|Ampseal adapter board]]
A pair of adaptor boards (see images to right) are available and shipped with the current drop-in boards. These enable the ERNI Microbridge connector from the resolver to be connected to the required pins on the Ampseal connector. Design files for these boards will be posted on github at some point - if you need a copy in the meantime contact user 'CJW' or post on the i3 controller hacking thread.

'''Code Update for Gate Driver Board - SPI Commication'''

The BMW i3 gate driver board communicates the DC bus voltage (ie traction battery voltage) and IGBT heatsink temperatures to the Openinverter via SPI.

On the Openinverter mini mainboard, pin 17 on JP2 is normally used as an 'Error Output'. When used with the BMW i3, this pin must instead be used for the SPI Clock signal.

To avoid the clock signal being pulled high or low by the pin acting as an Error Output, find this section of code in vehiclecontrol.cpp:<syntaxhighlight lang="cpp">
//Brake pin is used as SPI_MISO
DigIo::brk_out.Configure(GPIOC, GPIO5, PinMode::INPUT_FLT);

</syntaxhighlight>and insert these lines of code below it, to disable the Error Output:<syntaxhighlight lang="cpp">
//Disable err_out so it doesn't pull the clock signal up or down
DigIo::err_out.Configure(GPIOC, GPIO10, PinMode::INPUT_FLT);
</syntaxhighlight>

'''Openinverter Parameters'''

As of 12 April 2024, page 10 of the forum i3 controller hacking thread (link posted at the top of this page) contains an initial set of parameters that were successfully used for bench testing a motor with a pair of lead acid car batteries. Will update and eventually post a full set of parameters here once the motor is properly set up and has been tested with a high voltage battery.

'''Future Development'''

List of tasks to be completed to enable full use of these motors:

# Motor temperature sensor to be mapped and added to code
# Design files for adaptor boards posted to github

[[Category:OEM]] [[Category:BMW]] [[Category:Inverter]]

BMW i3 Inverter

2024-04-18T21:19:39Z

CJW: Updated list of mods required to use the drop-in board

BMW I3 inverter
[[File:BMW I3 inverter.jpg|thumb|BMW I3 inverter]]

Forum thread: https://openinverter.org/forum/viewtopic.php?p=23214#p23214

BMW i3™ inverter drop-in board Available

https://openinverter.org/shop/index.php?route=product/product&product_id=72

'''Overview'''

There are 2 variants of the i3, the standard i3 with motor power rated at 125kW and the i3s rated at 135kW.

There are 2 subvariants, as REX versions have an additional 25kw inverter and onboard generator.

Power stage: [https://www.infineon.com/dgdl/Infineon-HybridPACK2_Power_Modules-PB-v01_00-EN.pdf?fileId=db3a3043353fdc16013557f17ce67b60 Infineon FS800R07] IGBTs rated for 800amps 650v

'''Openinverter Drop-in Board'''
[[File:Openinverter i3 drop-in board.jpg|thumb|300x300px|Openinverter i3 drop-in board]]
The drop-in board houses the openinverter, generates 32V for the gate driver board, communicates via SPI with the gate driver board to obtain voltage and temperature readouts, and provides outputs to operate contactors.

As of 18 April 2024, the following mods are required to use these boards:

# Motor resolver and temperature sensor connector needs to be linked to the correct ampseal pins (this can be done with an additional pair of PCBs)
# Check solder connections on the 40 pin surface mount Harwin connector to the gate driver board for dry joints or shorts
# Apply code update in section below to prevent err_out pin on openinverter interfering with SPI communications
# Pin 35 of the Harwin connector to the gate driver board is not connected to anything, but testing indicates this must be powered for the gate driver to work, at least on some boards. The motor has been run successfully with 5V to this pin from the opeinverter power supply and an inline 10K resistor.

Pinouts for the three connectors on this board below.

{| class="wikitable"
|+ Pinout for Ampseal Plug
|-
! Pin No !! Assigniment !! Description
|-
| 1|| 12V ||
|-
| 2|| BRAKE_IN ||
|-
| 3|| PRECHARGE_OUT ||
|-
| 4|| CANL ||
|-
| 5|| CANH ||
|-
| 6|| DCSW_OUT ||
|-
| 7|| FORWARD_IN ||
|-
| 8|| REVERSE_IN ||
|-
| 9|| 5V (OUT) ||
|-
| 10|| RESOLVER_S2/ENCODER_A || Sin Hi
|-
| 11|| GND ||
|-
| 12|| RESOLVER_S1 || Sin Lo
|-
| 13|| THROTTLE1 ||
|-
| 14|| THROTTLE2 ||
|-
| 15|| RESOLVER_R1 || Ex Hi
|-
| 16|| RESOLVER_S3/ENCODER_B || Cos Hi
|-
| 17|| MTEMP+ ||
|-
| 18|| MTEMP- ||
|-
| 19|| RESOLVER_S4 || Cos Lo
|-
| 20|| EMCYSTOP_IN ||
|-
| 21 || GND ||
|-
| 22|| RESOLVER_R2 || Ex Lo
|-
| 23|| START_IN ||
|}

{| class="wikitable"
|+Pinout for Gate Driver Board
!Pin No
!I/O
!Description
!Notes
!
!Pin No
!I/O
!Description
!Notes
|-
|1
|
|
|
|
|21
|
|GND Switching Mosfets ?
|
|-
|2
|I
|32V in
|
|
|22
|
|GND Switching Mosfets ?
|
|-
|3
|I
|32V in
|
|
|23
|
|
|
|-
|4
|I
|IGBT A HI
|
|
|24
|
|
|
|-
|5
|I
|IGBT A LOW
|
|
|25
|
|
|
|-
|6
|I
|'''CS (ADC)'''
|
|
|26
|
|GND IGBT Driver ground
|
|-
|7
|I
|'''SDI'''
|
|
|27
|
|GND IGBT Driver ground
|
|-
|8
|I
|'''SDO'''
|
|
|28
|
|GND IGBT Driver ground
|
|-
|9
|I
|'''SCK'''
|
|
|29
|
|GND IGBT Driver ground
|
|-
|10
|I
|IGBT B HI
|
|
|30
|
|GND IGBT Driver ground
|
|-
|11
|I
|IGBT B LOW
|
|
|31
|
|GND IGBT Driver ground
|
|-
|12
|I
|IGBT C HI
|
|
|32
|
|GND IGBT Driver ground
|
|-
|13
|I
|IGBT C LOW
|
|
|33
|
|5V IGBT Driver Power
|
|-
|14
|
|
|
|
|34
|
|5V IGBT Driver Power
|
|-
|15
|
|
|
|
|35
|I
|IGBT PSU 12V on
|
|-
|16
|O
|IGBT DRIVER UVW Upper Ready
|
|
|36
|O
|IGBT Driver Fault
|
|-
|17
|O
|IGBT DRIVER UVW Lower Ready
|
|
|37
|I
|5V LEM Current sensor Power
|
|-
|18
|O
|Current Sense C Signal
|
|
|38
|
|GND Current sensor Ground
|
|-
|19
|O
|Current Sense B Signal
|
|
|39
|
|GND Current sensor Ground
|
|-
|20
|O
|Current Sense A Signal
|
|
|40
|
|GND Current sensor Ground
|
|}

'''Motor Resolver & Temperature Sensors'''

12-pin PCB header to connect to the motor sensors is an ERNI MiniBridge, part number 294920

Wire colours to pin allocation below determined by schematic and multimeter trace, with resolver coils and temperature sensors checked for resistance. Confirmed with motor bench test. [[File:ERNI Minibridge Connector.jpg|thumb|ERNI Minibridge Connector. Dots indicate pin 1.]]
{| class="wikitable"
|+Pinout for ERNI Microbridge
!Pin No
!Colour
!Description
!Notes
|-
|1
|Brown
|Sin Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω.
|-
|2
|Blue
|Sin Lo
|-
|3
|Yellow
|Ex Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω
|-
|4
|Green
|Ex Lo
|-
|5
|Red
|Cos Hi
| rowspan="2" |Twisted pair. 13.6 - 20.4 Ω
|-
|6
|White
|Cos Lo
|-
|7
|Blue
| rowspan="2" |Temperature
Sensor
| rowspan="4" |From BMW Service Technical Training Manual - I01 High-voltage Components:
There are two stator coil temperature sensors.

The rotor temperature is determined using readings from the stator temperature sensors.
|-
|8
|Grey
|-
|9
|Red
| rowspan="2" |Temperature
Sensor
|-
|10
|Grey
|-
|11
| -
|Unused
| rowspan="2" |These wires terminate in one of the six pin connectors in the motor housing. There is nothing connected to them.
|-
|12
| -
|Unused
|}

'''Motor Resolver & Temperature Sensor Adaptor Boards'''
[[File:ERNI Microbridge adapter board.png|thumb|300x300px|ERNI Microbridge adapter board]]
[[File:Ampseal board.png|thumb|300x300px|Ampseal adapter board]]
A pair of adaptor boards (see images to right) are available and shipped with the current drop-in boards. These enable the ERNI Microbridge connector from the resolver to be connected to the required pins on the Ampseal connector. Design files for these boards will be posted on github at some point - if you need a copy in the meantime contact user 'CJW' or post on the i3 controller hacking thread.

'''Code Update for Gate Driver Board - SPI Commication'''

The BMW i3 gate driver board communicates the DC bus voltage (ie traction battery voltage) and IGBT heatsink temperatures to the Openinverter via SPI.

On the Openinverter mini mainboard, pin 17 on JP2 is normally used as an 'Error Output'. When used with the BMW i3, this pin must instead be used for the SPI Clock signal.

To avoid the clock signal being pulled high or low by the pin acting as an Error Output, find this section of code in vehiclecontrol.cpp:<syntaxhighlight lang="cpp">
//Brake pin is used as SPI_MISO
DigIo::brk_out.Configure(GPIOC, GPIO5, PinMode::INPUT_FLT);

</syntaxhighlight>and insert these lines of code below it, to disable the Error Output:<syntaxhighlight lang="cpp">
//Disable err_out so it doesn't pull the clock signal up or down
DigIo::err_out.Configure(GPIOC, GPIO10, PinMode::INPUT_FLT);
</syntaxhighlight>

'''Openinverter Parameters'''

As of 12 April 2024, page 10 of the forum i3 controller hacking thread (link posted at the top of this page) contains an initial set of parameters that were successfully used for bench testing a motor with a pair of lead acid car batteries. Will update and eventually post a full set of parameters here once the motor is properly set up and has been tested with a high voltage battery.

'''Future Development'''

List of tasks to be completed to enable full use of these motors:

# Motor temperature sensor to be mapped and added to code
# Design files for adaptor boards posted to github

[[Category:OEM]] [[Category:BMW]] [[Category:Inverter]]

BMW i3 Inverter

2024-04-12T11:24:01Z

CJW: Added reference to forum thread

BMW I3 inverter
[[File:BMW I3 inverter.jpg|thumb|BMW I3 inverter]]

Forum thread: https://openinverter.org/forum/viewtopic.php?p=23214#p23214

BMW i3™ inverter drop-in board Available

https://openinverter.org/shop/index.php?route=product/product&product_id=72

'''Overview'''

There are 2 variants of the i3, the standard i3 with motor power rated at 125kW and the i3s rated at 135kW.

There are 2 subvariants, as REX versions have an additional 25kw inverter and onboard generator.

Power stage: [https://www.infineon.com/dgdl/Infineon-HybridPACK2_Power_Modules-PB-v01_00-EN.pdf?fileId=db3a3043353fdc16013557f17ce67b60 Infineon FS800R07] IGBTs rated for 800amps 650v

'''Openinverter Drop-in Board'''
[[File:Openinverter i3 drop-in board.jpg|thumb|300x300px|Openinverter i3 drop-in board]]
The drop-in board houses the openinverter, generates 32V for the gate driver board, communicates via SPI with the gate driver board to obtain voltage and temperature readouts, and provides outputs to operate contactors.

As of 12 April 2024, the following mods are required to use these boards:

# Check solder connections on the 40 pin surface mount Harwin connector to the gate driver board for dry joints or shorts
# Apply code update in section below to prevent err_out pin on openinverter interfering with SPI communications
# Pin 35 of the Harwin connector to the gate driver board is not connected to anything, but testing indicates this must be powered for the gate driver to work, at least on some boards. Voltage required at pin to be confirmed.

Pinouts for the three connectors on this board below.

{| class="wikitable"
|+ Pinout for Ampseal Plug
|-
! Pin No !! Assigniment !! Description
|-
| 1|| 12V ||
|-
| 2|| BRAKE_IN ||
|-
| 3|| PRECHARGE_OUT ||
|-
| 4|| CANL ||
|-
| 5|| CANH ||
|-
| 6|| DCSW_OUT ||
|-
| 7|| FORWARD_IN ||
|-
| 8|| REVERSE_IN ||
|-
| 9|| 5V (OUT) ||
|-
| 10|| RESOLVER_S2/ENCODER_A || Sin Hi
|-
| 11|| GND ||
|-
| 12|| RESOLVER_S1 || Sin Lo
|-
| 13|| THROTTLE1 ||
|-
| 14|| THROTTLE2 ||
|-
| 15|| RESOLVER_R1 || Ex Hi
|-
| 16|| RESOLVER_S3/ENCODER_B || Cos Hi
|-
| 17|| MTEMP+ ||
|-
| 18|| MTEMP- ||
|-
| 19|| RESOLVER_S4 || Cos Lo
|-
| 20|| EMCYSTOP_IN ||
|-
| 21 || GND ||
|-
| 22|| RESOLVER_R2 || Ex Lo
|-
| 23|| START_IN ||
|}

{| class="wikitable"
|+Pinout for Gate Driver Board
!Pin No
!I/O
!Description
!Notes
!
!Pin No
!I/O
!Description
!Notes
|-
|1
|
|
|
|
|21
|
|GND Switching Mosfets ?
|
|-
|2
|I
|32V in
|
|
|22
|
|GND Switching Mosfets ?
|
|-
|3
|I
|32V in
|
|
|23
|
|
|
|-
|4
|I
|IGBT A HI
|
|
|24
|
|
|
|-
|5
|I
|IGBT A LOW
|
|
|25
|
|
|
|-
|6
|I
|'''CS (ADC)'''
|
|
|26
|
|GND IGBT Driver ground
|
|-
|7
|I
|'''SDI'''
|
|
|27
|
|GND IGBT Driver ground
|
|-
|8
|I
|'''SDO'''
|
|
|28
|
|GND IGBT Driver ground
|
|-
|9
|I
|'''SCK'''
|
|
|29
|
|GND IGBT Driver ground
|
|-
|10
|I
|IGBT B HI
|
|
|30
|
|GND IGBT Driver ground
|
|-
|11
|I
|IGBT B LOW
|
|
|31
|
|GND IGBT Driver ground
|
|-
|12
|I
|IGBT C HI
|
|
|32
|
|GND IGBT Driver ground
|
|-
|13
|I
|IGBT C LOW
|
|
|33
|
|5V IGBT Driver Power
|
|-
|14
|
|
|
|
|34
|
|5V IGBT Driver Power
|
|-
|15
|
|
|
|
|35
|I
|IGBT PSU 12V on
|
|-
|16
|O
|IGBT DRIVER UVW Upper Ready
|
|
|36
|O
|IGBT Driver Fault
|
|-
|17
|O
|IGBT DRIVER UVW Lower Ready
|
|
|37
|I
|5V LEM Current sensor Power
|
|-
|18
|O
|Current Sense C Signal
|
|
|38
|
|GND Current sensor Ground
|
|-
|19
|O
|Current Sense B Signal
|
|
|39
|
|GND Current sensor Ground
|
|-
|20
|O
|Current Sense A Signal
|
|
|40
|
|GND Current sensor Ground
|
|}

'''Motor Resolver & Temperature Sensors'''

12-pin PCB header to connect to the motor sensors is an ERNI MiniBridge, part number 294920

Wire colours to pin allocation below determined by schematic and multimeter trace, with resolver coils and temperature sensors checked for resistance. Confirmed with motor bench test. [[File:ERNI Minibridge Connector.jpg|thumb|ERNI Minibridge Connector. Dots indicate pin 1.]]
{| class="wikitable"
|+Pinout for ERNI Microbridge
!Pin No
!Colour
!Description
!Notes
|-
|1
|Brown
|Sin Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω.
|-
|2
|Blue
|Sin Lo
|-
|3
|Yellow
|Ex Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω
|-
|4
|Green
|Ex Lo
|-
|5
|Red
|Cos Hi
| rowspan="2" |Twisted pair. 13.6 - 20.4 Ω
|-
|6
|White
|Cos Lo
|-
|7
|Blue
| rowspan="2" |Temperature
Sensor
| rowspan="4" |From BMW Service Technical Training Manual - I01 High-voltage Components:
There are two stator coil temperature sensors.

The rotor temperature is determined using readings from the stator temperature sensors.
|-
|8
|Grey
|-
|9
|Red
| rowspan="2" |Temperature
Sensor
|-
|10
|Grey
|-
|11
| -
|Unused
| rowspan="2" |These wires terminate in one of the six pin connectors in the motor housing. There is nothing connected to them.
|-
|12
| -
|Unused
|}

'''Motor Resolver & Temperature Sensor Adaptor Boards'''
[[File:ERNI Microbridge adapter board.png|thumb|300x300px|ERNI Microbridge adapter board]]
[[File:Ampseal board.png|thumb|300x300px|Ampseal adapter board]]
A pair of adaptor boards (see images to right) are available and shipped with the current drop-in boards. These enable the ERNI Microbridge connector from the resolver to be connected to the required pins on the Ampseal connector. Design files for these boards will be posted on github at some point - if you need a copy in the meantime contact user 'CJW' or post on the i3 controller hacking thread.

'''Code Update for Gate Driver Board - SPI Commication'''

The BMW i3 gate driver board communicates the DC bus voltage (ie traction battery voltage) and IGBT heatsink temperatures to the Openinverter via SPI.

On the Openinverter mini mainboard, pin 17 on JP2 is normally used as an 'Error Output'. When used with the BMW i3, this pin must instead be used for the SPI Clock signal.

To avoid the clock signal being pulled high or low by the pin acting as an Error Output, find this section of code in vehiclecontrol.cpp:<syntaxhighlight lang="cpp">
//Brake pin is used as SPI_MISO
DigIo::brk_out.Configure(GPIOC, GPIO5, PinMode::INPUT_FLT);

</syntaxhighlight>and insert these lines of code below it, to disable the Error Output:<syntaxhighlight lang="cpp">
//Disable err_out so it doesn't pull the clock signal up or down
DigIo::err_out.Configure(GPIOC, GPIO10, PinMode::INPUT_FLT);
</syntaxhighlight>

'''Openinverter Parameters'''

As of 12 April 2024, page 10 of the forum i3 controller hacking thread (link posted at the top of this page) contains an initial set of parameters that were successfully used for bench testing a motor with a pair of lead acid car batteries. Will update and eventually post a full set of parameters here once the motor is properly set up and has been tested with a high voltage battery.

'''Future Development'''

List of tasks to be completed to enable full use of these motors:

# Required voltage for pin 35 of Harwin gate driver board connector to be confirmed
# Motor temperature sensor to be mapped and added to code
# Design files for adaptor boards posted to github

[[Category:OEM]] [[Category:BMW]] [[Category:Inverter]]

BMW i3 Inverter

2024-04-12T11:22:26Z

CJW: Formatting

BMW I3 inverter
[[File:BMW I3 inverter.jpg|thumb|BMW I3 inverter]]

Forum thread: https://openinverter.org/forum/viewtopic.php?p=23214#p23214

BMW i3™ inverter drop-in board Available

https://openinverter.org/shop/index.php?route=product/product&product_id=72

'''Overview'''

There are 2 variants of the i3, the standard i3 with motor power rated at 125kW and the i3s rated at 135kW.

There are 2 subvariants, as REX versions have an additional 25kw inverter and onboard generator.

Power stage: [https://www.infineon.com/dgdl/Infineon-HybridPACK2_Power_Modules-PB-v01_00-EN.pdf?fileId=db3a3043353fdc16013557f17ce67b60 Infineon FS800R07] IGBTs rated for 800amps 650v

'''Openinverter Drop-in Board'''
[[File:Openinverter i3 drop-in board.jpg|thumb|300x300px|Openinverter i3 drop-in board]]
The drop-in board houses the openinverter, generates 32V for the gate driver board, communicates via SPI with the gate driver board to obtain voltage and temperature readouts, and provides outputs to operate contactors.

As of 12 April 2024, the following mods are required to use these boards:

# Check solder connections on the 40 pin surface mount Harwin connector to the gate driver board for dry joints or shorts
# Apply code update in section below to prevent err_out pin on openinverter interfering with SPI communications
# Pin 35 of the Harwin connector to the gate driver board is not connected to anything, but testing indicates this must be powered for the gate driver to work, at least on some boards. Voltage required at pin to be confirmed.

Pinouts for the three connectors on this board below.

{| class="wikitable"
|+ Pinout for Ampseal Plug
|-
! Pin No !! Assigniment !! Description
|-
| 1|| 12V ||
|-
| 2|| BRAKE_IN ||
|-
| 3|| PRECHARGE_OUT ||
|-
| 4|| CANL ||
|-
| 5|| CANH ||
|-
| 6|| DCSW_OUT ||
|-
| 7|| FORWARD_IN ||
|-
| 8|| REVERSE_IN ||
|-
| 9|| 5V (OUT) ||
|-
| 10|| RESOLVER_S2/ENCODER_A || Sin Hi
|-
| 11|| GND ||
|-
| 12|| RESOLVER_S1 || Sin Lo
|-
| 13|| THROTTLE1 ||
|-
| 14|| THROTTLE2 ||
|-
| 15|| RESOLVER_R1 || Ex Hi
|-
| 16|| RESOLVER_S3/ENCODER_B || Cos Hi
|-
| 17|| MTEMP+ ||
|-
| 18|| MTEMP- ||
|-
| 19|| RESOLVER_S4 || Cos Lo
|-
| 20|| EMCYSTOP_IN ||
|-
| 21 || GND ||
|-
| 22|| RESOLVER_R2 || Ex Lo
|-
| 23|| START_IN ||
|}

{| class="wikitable"
|+Pinout for Gate Driver Board
!Pin No
!I/O
!Description
!Notes
!
!Pin No
!I/O
!Description
!Notes
|-
|1
|
|
|
|
|21
|
|GND Switching Mosfets ?
|
|-
|2
|I
|32V in
|
|
|22
|
|GND Switching Mosfets ?
|
|-
|3
|I
|32V in
|
|
|23
|
|
|
|-
|4
|I
|IGBT A HI
|
|
|24
|
|
|
|-
|5
|I
|IGBT A LOW
|
|
|25
|
|
|
|-
|6
|I
|'''CS (ADC)'''
|
|
|26
|
|GND IGBT Driver ground
|
|-
|7
|I
|'''SDI'''
|
|
|27
|
|GND IGBT Driver ground
|
|-
|8
|I
|'''SDO'''
|
|
|28
|
|GND IGBT Driver ground
|
|-
|9
|I
|'''SCK'''
|
|
|29
|
|GND IGBT Driver ground
|
|-
|10
|I
|IGBT B HI
|
|
|30
|
|GND IGBT Driver ground
|
|-
|11
|I
|IGBT B LOW
|
|
|31
|
|GND IGBT Driver ground
|
|-
|12
|I
|IGBT C HI
|
|
|32
|
|GND IGBT Driver ground
|
|-
|13
|I
|IGBT C LOW
|
|
|33
|
|5V IGBT Driver Power
|
|-
|14
|
|
|
|
|34
|
|5V IGBT Driver Power
|
|-
|15
|
|
|
|
|35
|I
|IGBT PSU 12V on
|
|-
|16
|O
|IGBT DRIVER UVW Upper Ready
|
|
|36
|O
|IGBT Driver Fault
|
|-
|17
|O
|IGBT DRIVER UVW Lower Ready
|
|
|37
|I
|5V LEM Current sensor Power
|
|-
|18
|O
|Current Sense C Signal
|
|
|38
|
|GND Current sensor Ground
|
|-
|19
|O
|Current Sense B Signal
|
|
|39
|
|GND Current sensor Ground
|
|-
|20
|O
|Current Sense A Signal
|
|
|40
|
|GND Current sensor Ground
|
|}

'''Motor Resolver & Temperature Sensors'''

12-pin PCB header to connect to the motor sensors is an ERNI MiniBridge, part number 294920

Wire colours to pin allocation below determined by schematic and multimeter trace, with resolver coils and temperature sensors checked for resistance. Confirmed with motor bench test. [[File:ERNI Minibridge Connector.jpg|thumb|ERNI Minibridge Connector. Dots indicate pin 1.]]
{| class="wikitable"
|+Pinout for ERNI Microbridge
!Pin No
!Colour
!Description
!Notes
|-
|1
|Brown
|Sin Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω.
|-
|2
|Blue
|Sin Lo
|-
|3
|Yellow
|Ex Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω
|-
|4
|Green
|Ex Lo
|-
|5
|Red
|Cos Hi
| rowspan="2" |Twisted pair. 13.6 - 20.4 Ω
|-
|6
|White
|Cos Lo
|-
|7
|Blue
| rowspan="2" |Temperature
Sensor
| rowspan="4" |From BMW Service Technical Training Manual - I01 High-voltage Components:
There are two stator coil temperature sensors.

The rotor temperature is determined using readings from the stator temperature sensors.
|-
|8
|Grey
|-
|9
|Red
| rowspan="2" |Temperature
Sensor
|-
|10
|Grey
|-
|11
| -
|Unused
| rowspan="2" |These wires terminate in one of the six pin connectors in the motor housing. There is nothing connected to them.
|-
|12
| -
|Unused
|}

'''Motor Resolver & Temperature Sensor Adaptor Boards'''
[[File:ERNI Microbridge adapter board.png|thumb|300x300px|ERNI Microbridge adapter board]]
[[File:Ampseal board.png|thumb|300x300px|Ampseal adapter board]]
A pair of adaptor boards (see images to right) are available and shipped with the current drop-in boards. These enable the ERNI Microbridge connector from the resolver to be connected to the required pins on the Ampseal connector. Design files for these boards will be posted on github at some point - if you need a copy in the meantime contact user 'CJW' or post on the i3 controller hacking thread.

'''Code Update for Gate Driver Board - SPI Commication'''

The BMW i3 gate driver board communicates the DC bus voltage (ie traction battery voltage) and IGBT heatsink temperatures to the Openinverter via SPI.

On the Openinverter mini mainboard, pin 17 on JP2 is normally used as an 'Error Output'. When used with the BMW i3, this pin must instead be used for the SPI Clock signal.

To avoid the clock signal being pulled high or low by the pin acting as an Error Output, find this section of code in vehiclecontrol.cpp:<syntaxhighlight lang="cpp">
//Brake pin is used as SPI_MISO
DigIo::brk_out.Configure(GPIOC, GPIO5, PinMode::INPUT_FLT);

</syntaxhighlight>and insert these lines of code below it, to disable the Error Output:<syntaxhighlight lang="cpp">
//Disable err_out so it doesn't pull the clock signal up or down
DigIo::err_out.Configure(GPIOC, GPIO10, PinMode::INPUT_FLT);
</syntaxhighlight>

'''Openinverter Parameters'''

As of 12 April 2024, page 10 of the forum thread contains an initial set of parameters that were successfully used for bench testing a motor with a pair of lead acid car batteries. Will update and eventually post a full set of parameters here once the motor is properly set up and has been tested with a high voltage battery.

'''Future Development'''

List of tasks to be completed to enable full use of these motors:

# Required voltage for pin 35 of Harwin gate driver board connector to be confirmed
# Motor temperature sensor to be mapped and added to code
# Design files for adaptor boards posted to github

[[Category:OEM]] [[Category:BMW]] [[Category:Inverter]]

BMW i3 Inverter

2024-04-12T11:21:19Z

CJW:

BMW I3 inverter
[[File:BMW I3 inverter.jpg|thumb|BMW I3 inverter]]

Forum thread: https://openinverter.org/forum/viewtopic.php?p=23214#p23214

BMW i3™ inverter drop-in board Available

https://openinverter.org/shop/index.php?route=product/product&product_id=72

'''Overview'''

There are 2 variants of the i3, the standard i3 with motor power rated at 125kW and the i3s rated at 135kW.

There are 2 subvariants, as REX versions have an additional 25kw inverter and onboard generator.

Power stage: [https://www.infineon.com/dgdl/Infineon-HybridPACK2_Power_Modules-PB-v01_00-EN.pdf?fileId=db3a3043353fdc16013557f17ce67b60 Infineon FS800R07] IGBTs rated for 800amps 650v

'''Openinverter Drop-in Board'''
[[File:Openinverter i3 drop-in board.jpg|thumb|300x300px|Openinverter i3 drop-in board]]
The drop-in board houses the openinverter, generates 32V for the gate driver board, communicates via SPI with the gate driver board to obtain voltage and temperature readouts, and provides outputs to operate contactors.

As of 12 April 2024, the following mods are required to use these boards:

# Check solder connections on the 40 pin surface mount Harwin connector to the gate driver board for dry joints or shorts
# Apply code update in section below to prevent err_out pin on openinverter interfering with SPI communications
# Pin 35 of the Harwin connector to the gate driver board is not connected to anything, but testing indicates this must be powered for the gate driver to work, at least on some boards. Voltage required at pin to be confirmed.

Pinouts for the three connectors on this board below.

{| class="wikitable"
|+ Pinout for Ampseal Plug
|-
! Pin No !! Assigniment !! Description
|-
| 1|| 12V ||
|-
| 2|| BRAKE_IN ||
|-
| 3|| PRECHARGE_OUT ||
|-
| 4|| CANL ||
|-
| 5|| CANH ||
|-
| 6|| DCSW_OUT ||
|-
| 7|| FORWARD_IN ||
|-
| 8|| REVERSE_IN ||
|-
| 9|| 5V (OUT) ||
|-
| 10|| RESOLVER_S2/ENCODER_A || Sin Hi
|-
| 11|| GND ||
|-
| 12|| RESOLVER_S1 || Sin Lo
|-
| 13|| THROTTLE1 ||
|-
| 14|| THROTTLE2 ||
|-
| 15|| RESOLVER_R1 || Ex Hi
|-
| 16|| RESOLVER_S3/ENCODER_B || Cos Hi
|-
| 17|| MTEMP+ ||
|-
| 18|| MTEMP- ||
|-
| 19|| RESOLVER_S4 || Cos Lo
|-
| 20|| EMCYSTOP_IN ||
|-
| 21 || GND ||
|-
| 22|| RESOLVER_R2 || Ex Lo
|-
| 23|| START_IN ||
|}

{| class="wikitable"
|+Pinout for Gate Driver Board
!Pin No
!I/O
!Description
!Notes
!
!Pin No
!I/O
!Description
!Notes
|-
|1
|
|
|
|
|21
|
|GND Switching Mosfets ?
|
|-
|2
|I
|32V in
|
|
|22
|
|GND Switching Mosfets ?
|
|-
|3
|I
|32V in
|
|
|23
|
|
|
|-
|4
|I
|IGBT A HI
|
|
|24
|
|
|
|-
|5
|I
|IGBT A LOW
|
|
|25
|
|
|
|-
|6
|I
|'''CS (ADC)'''
|
|
|26
|
|GND IGBT Driver ground
|
|-
|7
|I
|'''SDI'''
|
|
|27
|
|GND IGBT Driver ground
|
|-
|8
|I
|'''SDO'''
|
|
|28
|
|GND IGBT Driver ground
|
|-
|9
|I
|'''SCK'''
|
|
|29
|
|GND IGBT Driver ground
|
|-
|10
|I
|IGBT B HI
|
|
|30
|
|GND IGBT Driver ground
|
|-
|11
|I
|IGBT B LOW
|
|
|31
|
|GND IGBT Driver ground
|
|-
|12
|I
|IGBT C HI
|
|
|32
|
|GND IGBT Driver ground
|
|-
|13
|I
|IGBT C LOW
|
|
|33
|
|5V IGBT Driver Power
|
|-
|14
|
|
|
|
|34
|
|5V IGBT Driver Power
|
|-
|15
|
|
|
|
|35
|I
|IGBT PSU 12V on
|
|-
|16
|O
|IGBT DRIVER UVW Upper Ready
|
|
|36
|O
|IGBT Driver Fault
|
|-
|17
|O
|IGBT DRIVER UVW Lower Ready
|
|
|37
|I
|5V LEM Current sensor Power
|
|-
|18
|O
|Current Sense C Signal
|
|
|38
|
|GND Current sensor Ground
|
|-
|19
|O
|Current Sense B Signal
|
|
|39
|
|GND Current sensor Ground
|
|-
|20
|O
|Current Sense A Signal
|
|
|40
|
|GND Current sensor Ground
|
|}

'''Motor Resolver & Temperature Sensors'''

12-pin PCB header to connect to the motor sensors is an ERNI MiniBridge, part number 294920

Wire colours to pin allocation below determined by schematic and multimeter trace, with resolver coils and temperature sensors checked for resistance. Confirmed with motor bench test. [[File:ERNI Minibridge Connector.jpg|thumb|ERNI Minibridge Connector. Dots indicate pin 1.]]
{| class="wikitable"
|+Pinout for ERNI Microbridge
!Pin No
!Colour
!Description
!Notes
|-
|1
|Brown
|Sin Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω.
|-
|2
|Blue
|Sin Lo
|-
|3
|Yellow
|Ex Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω
|-
|4
|Green
|Ex Lo
|-
|5
|Red
|Cos Hi
| rowspan="2" |Twisted pair. 13.6 - 20.4 Ω
|-
|6
|White
|Cos Lo
|-
|7
|Blue
| rowspan="2" |Temperature
Sensor
| rowspan="4" |From BMW Service Technical Training Manual - I01 High-voltage Components:
There are two stator coil temperature sensors.

The rotor temperature is determined using readings from the stator temperature sensors.
|-
|8
|Grey
|-
|9
|Red
| rowspan="2" |Temperature
Sensor
|-
|10
|Grey
|-
|11
| -
|Unused
| rowspan="2" |These wires terminate in one of the six pin connectors in the motor housing. There is nothing connected to them.
|-
|12
| -
|Unused
|}

'''Motor Resolver & Temperature Sensor Adaptor Boards'''
[[File:ERNI Microbridge adapter board.png|thumb|300x300px|ERNI Microbridge adapter board]]
[[File:Ampseal board.png|thumb|300x300px|Ampseal adapter board]]
A pair of adaptor boards (see images to right) are available and shipped with the current drop-in boards. These enable the ERNI Microbridge connector from the resolver to be connected to the required pins on the Ampseal connector. Design files for these boards will be posted on github at some point - if you need a copy in the meantime contact user 'CJW' or post on the i3 controller hacking thread.
'''Code Update for Gate Driver Board - SPI Commication'''
'''Code Update for Gate Driver Board - SPI Commication'''

'''Code Update for Gate Driver Board - SPI Commication'''

The BMW i3 gate driver board communicates the DC bus voltage (ie traction battery voltage) and IGBT heatsink temperatures to the Openinverter via SPI.

On the Openinverter mini mainboard, pin 17 on JP2 is normally used as an 'Error Output'. When used with the BMW i3, this pin must instead be used for the SPI Clock signal.

To avoid the clock signal being pulled high or low by the pin acting as an Error Output, find this section of code in vehiclecontrol.cpp:<syntaxhighlight lang="cpp">
//Brake pin is used as SPI_MISO
DigIo::brk_out.Configure(GPIOC, GPIO5, PinMode::INPUT_FLT);

</syntaxhighlight>and insert these lines of code below it, to disable the Error Output:<syntaxhighlight lang="cpp">
//Disable err_out so it doesn't pull the clock signal up or down
DigIo::err_out.Configure(GPIOC, GPIO10, PinMode::INPUT_FLT);
</syntaxhighlight>

'''Openinverter Parameters'''

As of 12 April 2024, page 10 of the forum thread contains an initial set of parameters that were successfully used for bench testing a motor with a pair of lead acid car batteries. Will update and eventually post a full set of parameters here once the motor is properly set up and has been tested with a high voltage battery.

'''Future Development'''

List of tasks to be completed to enable full use of these motors:

# Required voltage for pin 35 of Harwin gate driver board connector to be confirmed
# Motor temperature sensor to be mapped and added to code
# Design files for adaptor boards posted to github

[[Category:OEM]] [[Category:BMW]] [[Category:Inverter]]

BMW i3 Inverter

2024-04-12T11:20:24Z

CJW:

BMW I3 inverter
[[File:BMW I3 inverter.jpg|thumb|BMW I3 inverter]]

Forum thread: https://openinverter.org/forum/viewtopic.php?p=23214#p23214

BMW i3™ inverter drop-in board Available

https://openinverter.org/shop/index.php?route=product/product&product_id=72

'''Overview'''

There are 2 variants of the i3, the standard i3 with motor power rated at 125kW and the i3s rated at 135kW.

There are 2 subvariants, as REX versions have an additional 25kw inverter and onboard generator.

Power stage: [https://www.infineon.com/dgdl/Infineon-HybridPACK2_Power_Modules-PB-v01_00-EN.pdf?fileId=db3a3043353fdc16013557f17ce67b60 Infineon FS800R07] IGBTs rated for 800amps 650v

'''Openinverter Drop-in Board'''
[[File:Openinverter i3 drop-in board.jpg|thumb|300x300px|Openinverter i3 drop-in board]]
The drop-in board houses the openinverter, generates 32V for the gate driver board, communicates via SPI with the gate driver board to obtain voltage and temperature readouts, and provides outputs to operate contactors.

As of 12 April 2024, the following mods are required to use these boards:

# Check solder connections on the 40 pin surface mount Harwin connector to the gate driver board for dry joints or shorts
# Apply code update in section below to prevent err_out pin on openinverter interfering with SPI communications
# Pin 35 of the Harwin connector to the gate driver board is not connected to anything, but testing indicates this must be powered for the gate driver to work, at least on some boards. Voltage required at pin to be confirmed.

Pinouts for the three connectors on this board below.

{| class="wikitable"
|+ Pinout for Ampseal Plug
|-
! Pin No !! Assigniment !! Description
|-
| 1|| 12V ||
|-
| 2|| BRAKE_IN ||
|-
| 3|| PRECHARGE_OUT ||
|-
| 4|| CANL ||
|-
| 5|| CANH ||
|-
| 6|| DCSW_OUT ||
|-
| 7|| FORWARD_IN ||
|-
| 8|| REVERSE_IN ||
|-
| 9|| 5V (OUT) ||
|-
| 10|| RESOLVER_S2/ENCODER_A || Sin Hi
|-
| 11|| GND ||
|-
| 12|| RESOLVER_S1 || Sin Lo
|-
| 13|| THROTTLE1 ||
|-
| 14|| THROTTLE2 ||
|-
| 15|| RESOLVER_R1 || Ex Hi
|-
| 16|| RESOLVER_S3/ENCODER_B || Cos Hi
|-
| 17|| MTEMP+ ||
|-
| 18|| MTEMP- ||
|-
| 19|| RESOLVER_S4 || Cos Lo
|-
| 20|| EMCYSTOP_IN ||
|-
| 21 || GND ||
|-
| 22|| RESOLVER_R2 || Ex Lo
|-
| 23|| START_IN ||
|}

{| class="wikitable"
|+Pinout for Gate Driver Board
!Pin No
!I/O
!Description
!Notes
!
!Pin No
!I/O
!Description
!Notes
|-
|1
|
|
|
|
|21
|
|GND Switching Mosfets ?
|
|-
|2
|I
|32V in
|
|
|22
|
|GND Switching Mosfets ?
|
|-
|3
|I
|32V in
|
|
|23
|
|
|
|-
|4
|I
|IGBT A HI
|
|
|24
|
|
|
|-
|5
|I
|IGBT A LOW
|
|
|25
|
|
|
|-
|6
|I
|'''CS (ADC)'''
|
|
|26
|
|GND IGBT Driver ground
|
|-
|7
|I
|'''SDI'''
|
|
|27
|
|GND IGBT Driver ground
|
|-
|8
|I
|'''SDO'''
|
|
|28
|
|GND IGBT Driver ground
|
|-
|9
|I
|'''SCK'''
|
|
|29
|
|GND IGBT Driver ground
|
|-
|10
|I
|IGBT B HI
|
|
|30
|
|GND IGBT Driver ground
|
|-
|11
|I
|IGBT B LOW
|
|
|31
|
|GND IGBT Driver ground
|
|-
|12
|I
|IGBT C HI
|
|
|32
|
|GND IGBT Driver ground
|
|-
|13
|I
|IGBT C LOW
|
|
|33
|
|5V IGBT Driver Power
|
|-
|14
|
|
|
|
|34
|
|5V IGBT Driver Power
|
|-
|15
|
|
|
|
|35
|I
|IGBT PSU 12V on
|
|-
|16
|O
|IGBT DRIVER UVW Upper Ready
|
|
|36
|O
|IGBT Driver Fault
|
|-
|17
|O
|IGBT DRIVER UVW Lower Ready
|
|
|37
|I
|5V LEM Current sensor Power
|
|-
|18
|O
|Current Sense C Signal
|
|
|38
|
|GND Current sensor Ground
|
|-
|19
|O
|Current Sense B Signal
|
|
|39
|
|GND Current sensor Ground
|
|-
|20
|O
|Current Sense A Signal
|
|
|40
|
|GND Current sensor Ground
|
|}

'''Motor Resolver & Temperature Sensors'''

12-pin PCB header to connect to the motor sensors is an ERNI MiniBridge, part number 294920

Wire colours to pin allocation below determined by schematic and multimeter trace, with resolver coils and temperature sensors checked for resistance. Confirmed with motor bench test. [[File:ERNI Minibridge Connector.jpg|thumb|ERNI Minibridge Connector. Dots indicate pin 1.]]
{| class="wikitable"
|+Pinout for ERNI Microbridge
!Pin No
!Colour
!Description
!Notes
|-
|1
|Brown
|Sin Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω.
|-
|2
|Blue
|Sin Lo
|-
|3
|Yellow
|Ex Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω
|-
|4
|Green
|Ex Lo
|-
|5
|Red
|Cos Hi
| rowspan="2" |Twisted pair. 13.6 - 20.4 Ω
|-
|6
|White
|Cos Lo
|-
|7
|Blue
| rowspan="2" |Temperature
Sensor
| rowspan="4" |From BMW Service Technical Training Manual - I01 High-voltage Components:
There are two stator coil temperature sensors.

The rotor temperature is determined using readings from the stator temperature sensors.
|-
|8
|Grey
|-
|9
|Red
| rowspan="2" |Temperature
Sensor
|-
|10
|Grey
|-
|11
| -
|Unused
| rowspan="2" |These wires terminate in one of the six pin connectors in the motor housing. There is nothing connected to them.
|-
|12
| -
|Unused
|}
'''Motor Resolver & Temperature Sensor Adaptor Boards'''

'''Motor Resolver & Temperature Sensor Adaptor Boards'''
[[File:ERNI Microbridge adapter board.png|thumb|300x300px|ERNI Microbridge adapter board]]
[[File:Ampseal board.png|thumb|300x300px|Ampseal adapter board]]
A pair of adaptor boards (see images to right) are available and shipped with the current drop-in boards. These enable the ERNI Microbridge connector from the resolver to be connected to the required pins on the Ampseal connector. Design files for these boards will be posted on github at some point - if you need a copy in the meantime contact user 'CJW' or post on the i3 controller hacking thread.
'''Code Update for Gate Driver Board - SPI Commication'''

'''Code Update for Gate Driver Board - SPI Commication'''

The BMW i3 gate driver board communicates the DC bus voltage (ie traction battery voltage) and IGBT heatsink temperatures to the Openinverter via SPI.

On the Openinverter mini mainboard, pin 17 on JP2 is normally used as an 'Error Output'. When used with the BMW i3, this pin must instead be used for the SPI Clock signal.

To avoid the clock signal being pulled high or low by the pin acting as an Error Output, find this section of code in vehiclecontrol.cpp:<syntaxhighlight lang="cpp">
//Brake pin is used as SPI_MISO
DigIo::brk_out.Configure(GPIOC, GPIO5, PinMode::INPUT_FLT);

</syntaxhighlight>and insert these lines of code below it, to disable the Error Output:<syntaxhighlight lang="cpp">
//Disable err_out so it doesn't pull the clock signal up or down
DigIo::err_out.Configure(GPIOC, GPIO10, PinMode::INPUT_FLT);
</syntaxhighlight>

'''Openinverter Parameters'''

As of 12 April 2024, page 10 of the forum thread contains an initial set of parameters that were successfully used for bench testing a motor with a pair of lead acid car batteries. Will update and eventually post a full set of parameters here once the motor is properly set up and has been tested with a high voltage battery.

'''Future Development'''

List of tasks to be completed to enable full use of these motors:

# Required voltage for pin 35 of Harwin gate driver board connector to be confirmed
# Motor temperature sensor to be mapped and added to code
# Design files for adaptor boards posted to github

[[Category:OEM]] [[Category:BMW]] [[Category:Inverter]]

BMW i3 Inverter

2024-04-12T11:19:08Z

CJW: Updated with summary of fixes required to drop-in boards, link to forum post on parameters used for successful bench test, additional information on resolver adaptor boards, and list of remaining tasks to be resolved.

BMW I3 inverter
[[File:BMW I3 inverter.jpg|thumb|BMW I3 inverter]]

Forum thread: https://openinverter.org/forum/viewtopic.php?p=23214#p23214

BMW i3™ inverter drop-in board Available

https://openinverter.org/shop/index.php?route=product/product&product_id=72

'''Overview'''

There are 2 variants of the i3, the standard i3 with motor power rated at 125kW and the i3s rated at 135kW.

There are 2 subvariants, as REX versions have an additional 25kw inverter and onboard generator.

Power stage: [https://www.infineon.com/dgdl/Infineon-HybridPACK2_Power_Modules-PB-v01_00-EN.pdf?fileId=db3a3043353fdc16013557f17ce67b60 Infineon FS800R07] IGBTs rated for 800amps 650v

'''Openinverter Drop-in Board'''
[[File:Openinverter i3 drop-in board.jpg|thumb|300x300px|Openinverter i3 drop-in board]]
The drop-in board houses the openinverter, generates 32V for the gate driver board, communicates via SPI with the gate driver board to obtain voltage and temperature readouts, and provides outputs to operate contactors.

As of 12 April 2024, the following mods are required to use these boards:

# Check solder connections on the 40 pin surface mount Harwin connector to the gate driver board for dry joints or shorts
# Apply code update in section below to prevent err_out pin on openinverter interfering with SPI communications
# Pin 35 of the Harwin connector to the gate driver board is not connected to anything, but testing indicates this must be powered for the gate driver to work, at least on some boards. Voltage required at pin to be confirmed.

Pinouts for the three connectors on this board below.

{| class="wikitable"
|+ Pinout for Ampseal Plug
|-
! Pin No !! Assigniment !! Description
|-
| 1|| 12V ||
|-
| 2|| BRAKE_IN ||
|-
| 3|| PRECHARGE_OUT ||
|-
| 4|| CANL ||
|-
| 5|| CANH ||
|-
| 6|| DCSW_OUT ||
|-
| 7|| FORWARD_IN ||
|-
| 8|| REVERSE_IN ||
|-
| 9|| 5V (OUT) ||
|-
| 10|| RESOLVER_S2/ENCODER_A || Sin Hi
|-
| 11|| GND ||
|-
| 12|| RESOLVER_S1 || Sin Lo
|-
| 13|| THROTTLE1 ||
|-
| 14|| THROTTLE2 ||
|-
| 15|| RESOLVER_R1 || Ex Hi
|-
| 16|| RESOLVER_S3/ENCODER_B || Cos Hi
|-
| 17|| MTEMP+ ||
|-
| 18|| MTEMP- ||
|-
| 19|| RESOLVER_S4 || Cos Lo
|-
| 20|| EMCYSTOP_IN ||
|-
| 21 || GND ||
|-
| 22|| RESOLVER_R2 || Ex Lo
|-
| 23|| START_IN ||
|}

{| class="wikitable"
|+Pinout for Gate Driver Board
!Pin No
!I/O
!Description
!Notes
!
!Pin No
!I/O
!Description
!Notes
|-
|1
|
|
|
|
|21
|
|GND Switching Mosfets ?
|
|-
|2
|I
|32V in
|
|
|22
|
|GND Switching Mosfets ?
|
|-
|3
|I
|32V in
|
|
|23
|
|
|
|-
|4
|I
|IGBT A HI
|
|
|24
|
|
|
|-
|5
|I
|IGBT A LOW
|
|
|25
|
|
|
|-
|6
|I
|'''CS (ADC)'''
|
|
|26
|
|GND IGBT Driver ground
|
|-
|7
|I
|'''SDI'''
|
|
|27
|
|GND IGBT Driver ground
|
|-
|8
|I
|'''SDO'''
|
|
|28
|
|GND IGBT Driver ground
|
|-
|9
|I
|'''SCK'''
|
|
|29
|
|GND IGBT Driver ground
|
|-
|10
|I
|IGBT B HI
|
|
|30
|
|GND IGBT Driver ground
|
|-
|11
|I
|IGBT B LOW
|
|
|31
|
|GND IGBT Driver ground
|
|-
|12
|I
|IGBT C HI
|
|
|32
|
|GND IGBT Driver ground
|
|-
|13
|I
|IGBT C LOW
|
|
|33
|
|5V IGBT Driver Power
|
|-
|14
|
|
|
|
|34
|
|5V IGBT Driver Power
|
|-
|15
|
|
|
|
|35
|I
|IGBT PSU 12V on
|
|-
|16
|O
|IGBT DRIVER UVW Upper Ready
|
|
|36
|O
|IGBT Driver Fault
|
|-
|17
|O
|IGBT DRIVER UVW Lower Ready
|
|
|37
|I
|5V LEM Current sensor Power
|
|-
|18
|O
|Current Sense C Signal
|
|
|38
|
|GND Current sensor Ground
|
|-
|19
|O
|Current Sense B Signal
|
|
|39
|
|GND Current sensor Ground
|
|-
|20
|O
|Current Sense A Signal
|
|
|40
|
|GND Current sensor Ground
|
|}

'''Motor Resolver & Temperature Sensors'''

12-pin PCB header to connect to the motor sensors is an ERNI MiniBridge, part number 294920

Wire colours to pin allocation below determined by schematic and multimeter trace, with resolver coils and temperature sensors checked for resistance. Confirmed with motor bench test. [[File:ERNI Minibridge Connector.jpg|thumb|ERNI Minibridge Connector. Dots indicate pin 1.]]
{| class="wikitable"
|+Pinout for ERNI Microbridge
!Pin No
!Colour
!Description
!Notes
|-
|1
|Brown
|Sin Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω.
|-
|2
|Blue
|Sin Lo
|-
|3
|Yellow
|Ex Hi
| rowspan="2" |Twisted pair. 22.4 - 33.6 Ω
|-
|4
|Green
|Ex Lo
|-
|5
|Red
|Cos Hi
| rowspan="2" |Twisted pair. 13.6 - 20.4 Ω
|-
|6
|White
|Cos Lo
|-
|7
|Blue
| rowspan="2" |Temperature
Sensor
| rowspan="4" |From BMW Service Technical Training Manual - I01 High-voltage Components:
There are two stator coil temperature sensors.

The rotor temperature is determined using readings from the stator temperature sensors.
|-
|8
|Grey
|-
|9
|Red
| rowspan="2" |Temperature
Sensor
|-
|10
|Grey
|-
|11
| -
|Unused
| rowspan="2" |These wires terminate in one of the six pin connectors in the motor housing. There is nothing connected to them.
|-
|12
| -
|Unused
|}
'''Motor Resolver & Temperature Sensor Adaptor Boards'''
[[File:ERNI Microbridge adapter board.png|thumb|300x300px|ERNI Microbridge adapter board]]
[[File:Ampseal board.png|thumb|300x300px|Ampseal adapter board]]
A pair of adaptor boards (see images to right) are available and shipped with the current drop-in boards. These enable the ERNI Microbridge connector from the resolver to be connected to the required pins on the Ampseal connector. Design files for these boards will be posted on github at some point - if you need a copy in the meantime contact user 'CJW' or post on the i3 controller hacking thread.

'''Code Update for Gate Driver Board - SPI Commication'''

The BMW i3 gate driver board communicates the DC bus voltage (ie traction battery voltage) and IGBT heatsink temperatures to the Openinverter via SPI.

On the Openinverter mini mainboard, pin 17 on JP2 is normally used as an 'Error Output'. When used with the BMW i3, this pin must instead be used for the SPI Clock signal.

To avoid the clock signal being pulled high or low by the pin acting as an Error Output, find this section of code in vehiclecontrol.cpp:<syntaxhighlight lang="cpp">
//Brake pin is used as SPI_MISO
DigIo::brk_out.Configure(GPIOC, GPIO5, PinMode::INPUT_FLT);

</syntaxhighlight>and insert these lines of code below it, to disable the Error Output:<syntaxhighlight lang="cpp">
//Disable err_out so it doesn't pull the clock signal up or down
DigIo::err_out.Configure(GPIOC, GPIO10, PinMode::INPUT_FLT);
</syntaxhighlight>

'''Openinverter Parameters'''

As of 12 April 2024, page 10 of the forum thread contains an initial set of parameters that were successfully used for bench testing a motor with a pair of lead acid car batteries. Will update and eventually post a full set of parameters here once the motor is properly set up and has been tested with a high voltage battery.

'''Future Development'''

List of tasks to be completed to enable full use of these motors:

# Required voltage for pin 35 of Harwin gate driver board connector to be confirmed
# Motor temperature sensor to be mapped and added to code
# Design files for adaptor boards posted to github

[[Category:OEM]] [[Category:BMW]] [[Category:Inverter]]

File:ERNI Microbridge adapter board.png

2024-04-12T11:07:03Z

CJW:

ERNI Microbridge adapter board

File:Ampseal board.png

2024-04-12T11:05:21Z

CJW:

Ampseal board

File:Openinverter i3 drop-in board.jpg

2024-04-12T10:31:04Z

CJW:

Openinverter i3 drop-in board mounted to inverter

BMW i3 Inverter

2023-12-24T23:09:50Z

CJW:

BMW i3 Inverter

2023-12-24T23:07:57Z

CJW:

BMW i3 Inverter

2023-12-24T23:04:17Z

CJW: Added paragraphs explaining code update to fix SPI communication with gate driver board.

BMW i3 Inverter

2023-12-03T11:03:34Z

CJW: Updated ampseal pinout to swap Sin Hi and Sin Lo pin assignment, which appeared to be incorrect based on the mini mainboard wiki page and also measuring motor angle using the encoder. Sin Lo and Cos Lo have a shared connection to S1S4 (JP1 pin 16) on the mini mainboard, which corresponds to pins 12 and 19 on the Ampseal.

BMW i3 Inverter

2023-11-19T21:41:24Z

CJW: Updated resolver pin descriptions

BMW i3 Inverter

2023-11-09T18:59:40Z

CJW: Clarified resolver sensor section

BMW i3 Inverter

2023-11-04T13:26:20Z

CJW:

BMW i3 Inverter

2023-11-04T13:22:02Z

CJW: Clarified explanation of resolver wiring.

BMW i3 Inverter

2023-11-04T13:19:15Z

CJW: Added motor sensor pinout for ERNI Minibridge connector

File:ERNI Minibridge Connector.jpg

2023-11-04T13:10:47Z

CJW:

ERNI Minibridge Connector

File:ERNI Minibridge.jpg

2023-11-04T13:05:59Z

CJW:

ERNI Minibridge Connector

BMW i3 Inverter

2023-11-04T11:43:03Z

CJW: Added note so it's clear resolver wire colours are unconfirmed

BMW i3 Inverter

2023-11-01T22:50:27Z

CJW: Added description of resolver connector and cables from forum posts.