openinverter.org wiki - User contributions [en]

Volvo Gear Selector

2026-03-18T06:55:24Z

Jason arnold: created basic page

== Overview ==
Found in Volvo XC40 (2017+)

== Connectors ==
Plug Housing: JAE MX34 family (12pin) MX34012SF1

== Pinout ==
TBC

== Control ==
TBC

Opel Power Steering Pump

2025-10-03T03:12:15Z

Jason arnold: Revised Mechanical Properties and added Fluid section

This type of power steering pump is made by TRW and used in the Opel/Vauxhall Astra G and Zafira A. It's called the "Type 2" or "TRW 2" pump and is known to be quite noisy.
[[File:Opel_Astra_Power_Steering_Pump.jpg|alt=|border|right|frameless]]
== Electrical Connection [https://openinverter.org/forum/viewtopic.php?p=3771#p3771] ==
[[File:TRW 2 Power Steering Pump.png|thumb|Schematic from the Opel Astra G]]

=== Pinout and Cables ===
{| class="wikitable"
|+Wire Colors and Functions
!Cable Color
!Gauge
!Function
|-
|Red
|10mm²
| +12V Supply
|-
|Brown
|10mm²
|Chassis Ground
|-
|Black
|0.75mm²
| +12V Ignition Signal
|-
|Blue-White
|0.75mm²
|Alternator Pin 61
|-
|Brown-White
|0.75mm²
|K-Bus Diagnostics
|}

=== Operation & Issues ===
To ensure a quick start up of the pump the signals on the Black and Blue-White wire need to be sequenced. The Black wire indicates that the ignition is on. This alone does not start the pump, probably to save battery capacity for starting the internal combustion engine. Only if there's voltage on the Blue-White wire present the pump starts. This would be connected to the alternator to indicate the engine is running and the alternator provides enough current to feed the power steering pump.

Connecting both wires together and feeding them +12V at the same time works as well, but results in slow spool up of the pump.

If the Black (+12V Ignition Signal) is connected to constant power rather than switched, the pump will still function, but there will be a parasitic draw of ~200mA when the vehicle is off. This was done experimentally to try sequencing the Blue-White wire with ignition power in order to have a faster start, but the spool up was still slow.

=== K-Bus Communications ===
The pump can be accessed for diagnostics via K-Bus. This has not been reverse engineered yet.

=== Power Consumption ===
The pump should be connected via an 80A fuse to the 12V. The initial current will be quite high, the idle current should be around 6A without delta pressure from the steering column.

=== LV Connectors ===
Two different sets of connectors have been seen on this pump:

1) TE/AMP Superseal 1.5 series

* Pump harness (F): 282087-1
* Mating socket (M): 282105-1
* Terminals: 183036-1 (20AWG)
* Seals: 281934-2 (2.4mm ID)

[[File:Opel_Astra_Power_Steering_Pump_Harness.jpg|alt=|border|frameless]]

2) Bosch Kompakt 1.a series

* Pump harness (F): 1 928 404 221
* Mating socket (M): 1 928 405 136
* Terminals: BDK 2.8 series

[[File:Opel Astra Power Steering Pump Harness (Bosch).jpg|border|frameless]]

== Mechanical Properties ==

=== Dimensions ===
TBD

=== Fittings ===
High pressure side (pump supply/outlet): M16x1.5 thread [https://youtu.be/GD5K6TmF5PY?t=350].

Low pressure side (pump return/inlet) is just a hose. The fitting on the reservoir is likely 10mm (3/8").

=== Mounting Bracket ===
WillFab Motorsport (WFM) produces a universal fit bracket for this pump. Available [https://www.willfabmotorsport.co.uk/collections/eps-cradles-brackets here] and [https://www.ebay.co.uk/str/wfmttc here].

== Fluid ==
The correct oil for this pump is Fuchs TITAN CHF202 (formerly known as Pentosin CHF202) or anything that fulfills the Opel requirement 19 40 766. It has a green color. [1]
[[Category:Opel]]
[[Category:Power Steering]]

Volvo Power Steering Pump

2025-10-03T03:10:58Z

Jason arnold: Fixed dead link in Mounting Bracket

== Part Numbers and Versions ==
[[Category:Volvo]]
[[Category:Power Steering]]
{| class="wikitable"
|+Part Numbers<ref>https://rusefi.com/forum/viewtopic.php?p=45946#p45946</ref>
!Part Number
!Vehicle Used in
!Comment
|-
|30636927
|2004-2013 C30 C70 V50 S40
|unverified
|-
|31202520
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36000075
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36000116
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36000772
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36000801
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36001211
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36001485
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36002698
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36050678
|2004-2013 C30 C70 V50 S40
|unverified
|-
|8603041
|2004-2013 C30 C70 V50 S40
|unverified
|-
|8603274
|2004-2013 C30 C70 V50 S40
|unverified
|}

== Electrical Connection ==
Input signals, start and stop conditions described in S40 service manual<ref>https://www.volvo-forums.com/attachments/s40my2005_suspensionsteering-pdf.7233/</ref>

The harness for the motor supply can be bought completely (Volvo Part Number: 30775461 <ref>https://usparts.volvocars.com/p/Volvo_2007_C30-24l-5-cylinder/Wiring-Harness-Cable-Harness-Power-Steering-Pump-Electrohydraulic-Power-Steering-Service-Solution-Servo-Pump/42906949/30775461.html (Backup: )</ref>) or just the connector. There is connector kits available online (avoid the pig-tail version as the cable is way undersized. [https://www.ebay.de/itm/264183247309?_nkw=Electric+Power+Steering+%28EPS%29+Pump+Wire+Connector+Kit+Type+1+Fit+for+Volvo+Ford&itmmeta=01J64V8R3PQKQS2EKGFX7V5BVM&hash=item3d828c71cd:g:9YsAAOSwkvtb3Qd3&itmprp=enc%3AAQAJAAABMHoV3kP08IDx%2BKZ9MfhVJKnq1cduF5WgneJWcf2KOIwYLjdi97A8lf5OlJCgf3lStwgB7DXBbzWP5qft6Wq1wk68P2yrbn6NspdbHXbMs%2Fo1lKpey0MBk2Dqf%2BYimnPZ2JcaYs6l1vtYvLq%2FTbkcfppJYbhQ6U1IcaY0%2BTcZ1LLNcMEsG1cAazAwdRpglFiU3VmsIb3MOC9ZgJtYJ0XEm8XvmXBFsGZb9PJlyyXlp5YtkKGxAAM0H0gjTcEUfTXFlbl8jiyw3ziYa%2FjJuc2Db%2B15Kf%2BAQY%2FhWSFyBkaSZK1%2FUit%2FC2tF3wKqv2UPWRrfcw1BV%2BWd1HzbLSbvObyYLAklc%2FNhtRoWci2FP0azltlwmEtiiOaGp4YI1cFSiJtqqDMZeeZSWI8j0AvO6hbAROI%3D%7Ctkp%3ABk9SR4CCo5uxZA Link])
[[File:Volvo eps connections.png|thumb|2011 Volvo S40 T5 Pump connectors]]

=== Connector A (Power)<ref name=":0">Volvo C30 2007 Schematic, TP39103202</ref> ===
{| class="wikitable"
|+Pinout
!Pin Number
!Cable Color
!Function
!Comment
|-
|1
|Red
| Permanent +12V for Motor
|Fused with 80A fuse (F2)
|-
|2
|Black
|GND
|
|}
{| class="wikitable"
|+
Volvo Part Numbers
!Part
!Part Number
!Comment
|-
|Housing
|31266849<ref>https://usparts.volvocars.com/p/Volvo_2007_C30-24l-5-cylinder/Receptacle-Housing-Cable-Harness-Engine-Component-Parts-Electrical-Power-Steering-Module-EPS/42815694/31266849.html</ref>
|Not verified, possibly different plug?
|-
|Housing
|30728420<ref>https://usparts.volvocars.com/p/Volvo_2011_S60-30l-6-cylinder-Turbo/Receptacle-Housing-Cable-Harness-Engine-Compartment-Component-Parts-Connector-Control-Module-Power-Steering-EHPS-Electrical-Power-Steering-Module-EPS-/42878531/30728420.html</ref>
|Not verified
|}
{| class="wikitable"
|+OEM (Yazaki) Part Numbers
!Part
!Part Number
!Comment
|-
|Housing
|7283-2918-10<ref>https://connector.yazaki-group.com/cgi-bin/english/detail.cgi?part_id=7283-2918-10</ref>
|Also in black, P/N 7283-2918-30
|-
|Terminals
|7116-3250<ref>https://connector.yazaki-group.com/cgi-bin/english/detail.cgi?part_id=7116-3250</ref>
|For 8mm2 wire
|-
|Wire Seals
|7158-3610-80<ref>https://connector.yazaki-group.com/cgi-bin/english/detail.cgi?part_id=7158%2D3610%2D80</ref>
|For 8mm2 wire
|}
Note: Some later Volvo models use a similar variant of this pump which has a different shaped (smooth housing body) Connector A. Not known if the CAN protocol is different.

=== Connector B (Control)<ref name=":0" /> ===
{| class="wikitable"
|+Pinout
!Pin Number
!Cable Color
!Function
!Comment
|-
|1
|Grey-Blue
|Ignition +12V for Control
|Fused with 10A fuse (F53).
|-
|2
|
|CAN-L
|
|-
|3
|
|CAN-H
|
|}

A visual guide of the pinout can be found on [https://www.maxxecu.com/webhelp/can_peripheral_control_volvo_powersteering.html this MaxxECU online help page]
{| class="wikitable"
|+
Volvo Part Numbers
!Part
!Part Number
!Comment
|-
|Connector
|31346135<ref>https://usparts.volvocars.com/p/Volvo_2007_C30-24l-5-cylinder/Receptacle-Housing-Electric-Power-Steering-EPAS-Electrical-Power-Steering-Module-PSCM/65250641/31346135.html</ref>
|Not verified
|}
{| class="wikitable"
|+OEM (Yazaki) Part Numbers
!Part
!Part Number
!Comment
|-
|Housing
|7283-8730-30<ref>https://connector.yazaki-group.com/cgi-bin/english/detail.cgi?part_id=7283-8730-30</ref>
|
|-
|Terminals
|7116-1680-02<ref>https://connector.yazaki-group.com/cgi-bin/english/detail.cgi?part_id=7116%2D1680%2D02</ref>
|
|-
|Wire Seals
|7157-3951-60<ref>https://connector.yazaki-group.com/cgi-bin/english/detail.cgi?part_id=7157%2D3951%2D60</ref>
|
|}

== CAN Bus Control ==
If it doesn't receive CAN messaging then the pump will run in "limp mode" at 75% of full speed.<ref>https://www.corral.net/threads/volvo-electric-power-steering-conversion-full-write-up.2499503/page-4?post_id=18735339#post-18735339</ref>

The CAN bus protocol has been reverse engineered in the RusEFI forum<ref>https://www.rusefi.com/forum/viewtopic.php?f=4&t=2329</ref> and a LUA script example exists<ref>https://github.com/rusefi/rusefi/blob/master/firmware/controllers/lua/examples/Volvo-electric-power-steering-pump.txt</ref>

Alternatively, there is an implementation using Arduino code<ref>https://github.com/NMSTEC/Volvo_EPS_FREE</ref>
== Mechanical Properties ==

=== Dimensions ===
Approx. 12" x 7" x 7" (305mm x 178mm x 178mm)

=== Fittings ===

* High pressure side (pump supply/outlet): M16x1.5 (you can use adapters like this one: https://www.ebay.de/itm/192079081475)
* Low pressure side (pump return/inlet) is just a hose. The fitting on the reservoir is likely 10mm (3/8").

=== Mounting Bracket ===
WillFab Motorsport (WFM) produces a universal fit bracket for this pump. Available [https://www.willfabmotorsport.co.uk/collections/eps-cradles-brackets here] and [https://www.ebay.co.uk/str/wfmttc here].

== Fluid ==
Pentosin CHF 202 is spec'd in the Volvo manual.

== References ==
<references />

Opel Power Steering Pump

2025-10-03T02:54:04Z

Jason arnold: Added "Operation & Issues" section

This type of power steering pump is made by TRW and used in the Opel/Vauxhall Astra G and Zafira A. It's called the "Type 2" or "TRW 2" pump and is known to be quite noisy.
[[File:Opel_Astra_Power_Steering_Pump.jpg|alt=|border|right|frameless]]

The correct oil for this pump is Fuchs TITAN CHF202 (formerly known as Pentosin CHF202) or anything that fulfills the Opel requirement 19 40 766. It has a green color. [https://openinverter.org/forum/download/file.php?id=12865]

== Electrical Connection [https://openinverter.org/forum/viewtopic.php?p=3771#p3771] ==
[[File:TRW 2 Power Steering Pump.png|thumb|Schematic from the Opel Astra G]]

=== Pinout and Cables ===
{| class="wikitable"
|+Wire Colors and Functions
!Cable Color
!Gauge
!Function
|-
|Red
|10mm²
| +12V Supply
|-
|Brown
|10mm²
|Chassis Ground
|-
|Black
|0.75mm²
| +12V Ignition Signal
|-
|Blue-White
|0.75mm²
|Alternator Pin 61
|-
|Brown-White
|0.75mm²
|K-Bus Diagnostics
|}

=== Operation & Issues ===
To ensure a quick start up of the pump the signals on the Black and Blue-White wire need to be sequenced. The Black wire indicates that the ignition is on. This alone does not start the pump, probably to save battery capacity for starting the internal combustion engine. Only if there's voltage on the Blue-White wire present the pump starts. This would be connected to the alternator to indicate the engine is running and the alternator provides enough current to feed the power steering pump.

Connecting both wires together and feeding them +12V at the same time works as well, but results in slow spool up of the pump.

If the Black (+12V Ignition Signal) is connected to constant power rather than switched, the pump will still function, but there will be a parasitic draw of ~200mA when the vehicle is off. This was done experimentally to try sequencing the Blue-White wire with ignition power in order to have a faster start, but the spool up was still slow.

=== K-Bus Communications ===
The pump can be accessed for diagnostics via K-Bus. This has not been reverse engineered yet.

=== Power Consumption ===
The pump should be connected via an 80A fuse to the 12V. The initial current will be quite high, the idle current should be around 6A without delta pressure from the steering column.

=== LV Connectors ===
Two different sets of connectors have been seen on this pump:

1) TE/AMP Superseal 1.5 series

* Pump harness (F): 282087-1
* Mating socket (M): 282105-1
* Terminals: 183036-1 (20AWG)
* Seals: 281934-2 (2.4mm ID)

[[File:Opel_Astra_Power_Steering_Pump_Harness.jpg|alt=|border|frameless]]

2) Bosch Kompakt 1.a series

* Pump harness (F): 1 928 404 221
* Mating socket (M): 1 928 405 136
* Terminals: BDK 2.8 series

[[File:Opel Astra Power Steering Pump Harness (Bosch).jpg|border|frameless]]

== Mechanical Connection and Dimensions ==
The hydraulic high pressure line has an M16x1.5 thread [https://youtu.be/GD5K6TmF5PY?t=350].

* Diameter: Return line
* Thread of high pressure line
* Mounting: Threads, Angle, ...
[[Category:Opel]]
[[Category:Power Steering]]

ZombieVerter VCU

2025-09-17T06:45:25Z

Jason arnold: Several formatting updates to headers and body for readability. Also added important note regarding availability of design files.

[[File:Zombie model.png|thumb|614x614px|ZombieVerter VCU board (NOTE: V1.2 is preproduction, V1.a is the current latest hardware revision)]]
==Introduction ==
'''An open-source EV conversion VCU (vehicle control unit) for controlling salvaged EV components!'''

Modern EV conversion projects often look to reuse salvaged parts from wrecked vehicles, such as the motors, batteries and chargers.

The issue is that each of these components and manufacturers, use different methods of control and communication.

Developing controllers for these devices is complex, and time consuming and often require very dedicated communication protocols. Instead of making custom boards for every part that's been decoded, why not just make a general purpose VCU (vehicle control unit) with a verity of different types of inputs and outputs?

'''''Introducing: the "ZombieVerter" VCU - a general purpose EV conversion VCU.'''''

With a large array of inputs/outputs, control logic, and a web interface for configuration and data logging. The ZombieVerter is a powerful, flexible and customizable VCU well suited for EV conversions.

It's also an open source project!

=== Features ===

==== Hardware: ====

* On-board WiFi
* 3x high side PWM drivers
* 5x low side outputs
* 3x input pins (pull to ground only)
* 3x CANbus interfaces
* LIN bus
* sync serial interface
* OBD-II interface
* etc.

==== Software: ====

* Web based user interface
* Contactor control
* Charger control
* Charge timer
* Motor (inverter) control
* Heater control
* Water pump control
* Coolant fan control
* Throttle mapping
* Motor regen
* BMS limits
* IVT shunt initialization
* Data logging and graphing
* etc.
=== Currently supported OEM hardware: ===
<nowiki>*</nowiki>This list is always growing and changing, and not everything is verified working

==== Motors/Drive units: ====

* [[Nissan leaf motors|Nissan Leaf Gen1/2/3 inverter/motor via CAN]]
* [[Lexus GS450h Drivetrain|Lexus GS450h inverter / L110 gearbox via sync serial]]
* Lexus GS300h inverter / L210 gearbox via sync serial
* Toyota Prius/Yaris/Auris Gen 3 inverters via sync serial

* [[:Category:Mitsubishi|Mitsubishi Outlander motors/inverter]]
* openinverter controller

==== Chargers/DCDCs: ====
* [[Nissan leaf pdm|Nissan Leaf PDM (Charger and DCDC)]] Gen1,2 & 3
* [[Mitsubishi Outlander DCDC OBC|Mitsubishi Outlander OBC (charger/DCDC)]]
* [[Tesla Model S/X DC/DC Converter|tesla model S dcdc]]
* [[BMW I3 Fast Charging LIM Module|CCS DC fast charge via BMW i3 LIM]] - type 2 + type 1
* [[Chademo with Zombieverter|Chademo DC fast charging]]
* [[Foccci|Foccci CCS faster charger controller]]
* [https://citini.com/product/evs-charge-port-controller/ EVS-Charge Port Controller]
* Elcon charger

==== Heaters: ====
*[[Volkswagen Heater|VAG/VW PTC water heater via LIN bus]]
*[[VAG PTC Air Heater|VAG/VW cabin heater via LIN bus]]

* [[Chevrolet Volt Water Heater|Opel Ampera / Chevy Volt 6.5kW cabin heater]]
* [[Mitsubishi Outlander Water Heater|Mitsubishi outlander hybrid water heater]]

==== BMS: ====
* [[Nissan Leaf BMS|Nissan leaf BMS]]/battery pack
* [[Renault Kangoo 36|kangoo bms]]
*orion bms
*[https://github.com/Tom-evnut/SimpBMS SimpBMS]
*[[Isabellenhütte Heusler|ISA shunt]]
*[[BMW Hybrid Battery Pack#S-Box|BMW SBOX]]
*VW EBOX

==== Vehicle Integration (for CANbus control of dash, etc.): ====
* 1998-2005 BMW 3-series (E46) CAN support
* 1996-2003 BMW 5-series (E39) CAN support
* 2001-2008 BMW 7-series (E65) CAN Support
* BMW E9x CAN support
* Mid-2000s VAG CAN support
* Subaru CAN support

== Resources ==

* [https://openinverter.org/forum/viewtopic.php?f=3&t=1277 Development thread]
* Purchasing:
** [https://www.evbmw.com/index.php/evbmw-webshop/vcu-boards/zombieverter-vcu-built Fully-built VCU boards]
** [https://www.evbmw.com/index.php/evbmw-webshop/vcu-boards/zombie-vcu Partially-built VCU boards]
* [https://github.com/damienmaguire/Stm32-vcu GitHub repo]
** Hardware: [https://github.com/damienmaguire/Stm32-vcu/tree/master/Hardware/Zombie ZombieVerter V1]*
** Software: [https://github.com/damienmaguire/Stm32-vcu/releases latest stable software release]

<nowiki>*</nowiki> '''IMPORTANT NOTE: only design files for PCB V1 are publicly available on GitHub, design files for the latest PCB release (V1.a) are only available through [https://www.patreon.com/c/evbmw/posts Damien Maguire's Patreon] and require membership at the Design Files tier or higher.'''

== Assembling the VCU ==
Looking to build a ZombieVerter VCU yourself or the kit is missing hardware?

* [[Zombiverter hardware]] page for additional build instructions

* [https://github.com/damienmaguire/Stm32-vcu Github with PCB, schematic, pin-outs, etc]

''The enclosure and header are required if you did not order a [https://www.evbmw.com/index.php/evbmw-webshop/vcu-boards/zombieverter-vcu-built '''fully built board''']''

VCU boards from the webshop, '''''come pre-programmed''''' and '''do not require any additional steps taken to work'''.

For programming a blank board see: [[zombieverter programing|ZombieVerter programming]]
===The enclosure kit options:===

# [https://www.aliexpress.com/item/32857771975.html?spm=a2g0s.9042311.0.0.39f24c4dWOmGPE Enclosure Kit with Header, connector and pins]<ref>https://www.aliexpress.com/item/32857771975.html?spm=a2g0s.9042311.0.0.39f24c4dWOmGPE (Backup: [https://web.archive.org/web/20220524004318/https://www.aliexpress.com/item/32857771975.html Web Archive])</ref>
#[https://www.aliexpress.com/item/32822692950.html Connector and pins]<ref>https://de.aliexpress.com/item/32822692950.html (Backup: [https://web.archive.org/web/20221119203700/https://www.aliexpress.us/item/2251832636378198.html?gatewayAdapt=glo2usa4itemAdapt&_randl_shipto=US Web Archive])</ref>
#[https://www.aliexpress.com/item/1005003512474442.html Pre-wired connector] <ref>https://www.aliexpress.com/item/1005003512474442.html (Backup: [http://web.archive.org/web/20221120105651/https://www.aliexpress.us/item/3256803326159690.html?gatewayAdapt=glo2usa4itemAdapt&_randl_shipto=US Web Archive])</ref>

The original connectors are from Aptiv (Delphi):

* [https://www.aptiv.com/en/solutions/connection-systems/catalog/item?id=13669859_en Aptiv 56-pin connector]
* [https://www.aptiv.com/en/solutions/connection-systems/catalog/item?id=33511394_en Aptiv 56-pin header]
* [https://www.tti.com/content/ttiinc/en/apps/part-detail.html?partsNumber=210S048&mfgShortname=FCA&productId=161404611 Removal tool for connector terminals: Manufacturer: Aptiv (formerly Delphi)] Part Number: 210S048
=== Videos on assembly, powering up, updating, etc: ===
https://www.youtube.com/watch?v=geZuIbGHh30&list=PLh-aHjjWGgLVCsAqaCL6_jmn_QqhVlRiG

https://www.youtube.com/watch?v=_JRa_uFyVkY&list=PLh-aHjjWGgLUWaetAmShkv6gmvk7vLaHd

== Wiring ==
[[File:ZombieVerter VCU V1 cable side pinout2.jpg|thumb|alt=|VCU pinout diagram |513x513px]]Each device requires different wiring setups, settings and power requirements.

<nowiki>*</nowiki>cross referencing OEM wiring diagrams is highly recommended

=== Vehicle-specific configurations ===
* [[GS450H with zombieverter|GS450H with ZombieVerter]]
* [[Leaf stack with zombiverter|Leaf stack with ZombiVerter]]
* [[Tesla SDU with Zombieverter|Tesla SDU with ZombieVerter]]
* [[Chademo with Zombieverter]]

=== Power wiring ===
The ZombieVerter requires a permanent 12V supply. This is so it can manage charging, timers, and monitor systems when the car is at rest.

The average power draw, at idle, is 150 mA.

* Pin 55 to 12V- ground
* Pin 56 to 12V+ positive

The ZombieVerter controls power/"ignition" signals to other devices (inverters, chargers, and DCDC converters), powering those devices when required. This is done by triggering an external 12V relay. '''''ZombieVerter controls the external relay using low-side switching'', meaning that it pulls the ground pin of the relay to ground.'''

* [[File:Gernice-zombie.png|thumb|583x583px|general zombie and battery box wiring]]Pin 32 to ground pin on a 12V relay
* Relay positive pin to 12V+
* One of the relays switch pin to 12V+

This effectively provides a switched 12V supply, controlled by the ZombieVerter.

Used to switch "enable" mode to devices via:

* Leaf inverter enable pin
* Leaf PDM enable pin
* Mitsubisihi OBC enable pin

=== Contactor wiring ===
The Zombieveter manages the Negative, Positive and PreCharge contactors in an EV conversion.

This is done based off a series of voltage measurements (UDC), this voltage value (UDC) can be supplied from a variety of sources:

* ISA IVT shunt
* Nissan leaf inverter
* BMW S-BOX
* etc.

''Without a proper UDC measurement, the ZombieVerter '''will fail precharge and never go into run mode.'''''

'''The contactor control pins on the ZombieVerter are ''low-side switching'', meaning that they pull to ground.'''

The positive leads from the contactors need to be connected to 12V+ and the ground leads to:

* Pin 31 for the negative contactor
* Pin 33 for the positive contactor
* Pin 34 for the pre-charge contactor
=== Throttle pedal wiring ===
The ZombieVerter supports dual-channel throttle. This redundancy is for safety in case one channel fails or drops out. It's highly recommended to use dual-channel throttle. Single-channel is an option.

Connect the following to the ZombieVerter pins:

* Pin 45 to throttle grounds
* Pin 46 to throttle channel 2
* Pin 47 to throttle channel 1
* Pin 48 to throttle positives

=== Start, Run, and Direction wiring ===
The ZombieVerter requires 2 inputs to get into "drive" mode. '''These pins need to be ''pulled high'' (connected to 12V +)'''

* Pin 15 to "on" switched input (key switched to "on")
* Pin 52 to "start" momentary input (momentary key switched "ignition")

==== Forward and Reverse ====
These pins need to be ''pulled high'' (connected to 12V +)

* Pin 53 reverse
* Pin 54 forward

==== Brake signal ====

* Pin 49 need to be ''pulled high'' (connected to 12V +) when brake is pressed

=== Input/output pins ===
The ZombieVerter has a number of selectable input/output pins that can be used for a number of functions. These pins are:

Low side Outputs.

*GP Out 3
*GP Out 2
* Neg Contactor switch/GP Out 1
*Trans SL1- (If not using the GS450H)
*Trans SL2- (If not using the GS450H)

'''*Low side output connect to ground when activated.'''

The low side outputs in Zombie are ideal for switching relays, such as for coolant pumps.

High side PWM.

*PWM 3
*PWM 2
*PWM 1
*Pump PWM - Limited to GS450 Oil pump pwm or tacho pwm output

These are high side 12V outputs, usually for controlling gauges or auxiliary items than need a pwm signals.

'''*not suitable for controlling relays.'''

Ground Input pins

These pins pull down to ground only. '''Do not connect any voltage to these pins.'''

PB1

PB2

PB3

=== Pin functions: ===
''Note: While the web interface will allow you to select input pins or output pins, some will not actually work.''

''example: a input switch wired but set to negContactor''
{| class="wikitable"
|+
!Pin
!IN/OUT/PWM
!Function
|-
|ChaDemoAIw
|'''OUTPUT'''
|activates when Chademo charger handshake initiates
|-
|OBCEnable
|'''OUTPUT'''
|activates as part of the ExtCharger module
|-
|HeaterEnable
|'''OUTPUT'''
|activates only in run mode and when coolant pump is on*
|-
|RunIndication
|'''OUTPUT'''
|activates when zombie is in run mode
|-
|WarnIndication
|'''OUTPUT'''
|activates when a error occurs with the ZombieVerter
|-
|CoolantPump
|'''OUTPUT'''
|activates during precharge, usually used for coolant pumps
|-
|NegContactor
|'''OUTPUT'''
|activates when the negative contactor needs to be closed. ie precharge, run, charge mode, etc
|-
|BrakeLight
|'''OUTPUT'''
|activates when a set brake light on threshold value is met
|-
|ReverseLight
|'''OUTPUT'''
|activates when reverse direction is selected
|-
|CoolingFan
|'''OUTPUT'''
|activates when FanTemp setpoint is reached
|-
|HVActive
|'''OUTPUT'''
|activates when contactors are closed and VCU is in run or charge mode
|-
|BrakeVacPump
|'''DIGITAL OUTPUT'''
|activates when BrakeVacSensor threshold value is met
|-
|CpSpoof
|'''PWM OUTPUT'''
|used to spoof CP signal to OBC when using a charging interface such as FOCCCI or I3LIM
|-
|GS450Hpump
|'''PWM OUTPUT'''
|used to run GS450H oil pump
|-
|HeatReq
|'''DIGITAL INPUT'''
|
|-
|HVRequest
|'''DIGITAL INPUT'''
|NOT FUNCTIONING
|-
|DCFCRequest
|'''DIGITAL INPUT'''
|Chademo Charge Interface enable contactors to charge
|-
|ProxPilot
|'''ANALOGUE INPUT'''
|detects when charge cable is plugged in
|-
|BrakeVacSensor
|'''ANALOGUE INPUT'''
|vacuum sensor input, use for triggering BrakeVacPump '''DIGITAL OUTPUT'''
|-
|PWMTim3
|
|
|}

==== Proximity Pilot====
This analogue input used to detect a charging cable is plugged in.
[[File:ZombiePP.png|none|thumb]]
A resistor to the 5v needs to be connected to the analogue in pin, 330 ohms in the spec, and R5 needs to be another resistor between analogue in pin and ground. Type 1 connectors should be a 2.7k ohm resistor and type 2 should be 4.7k ohm. Note the charging port may already have this resistor installed.

Open up the Zombie UI and choose ProxPilot for the function of the analogue in pin. Then start plotting PPVal and then plug in, you can then use this to select your PPThreshold. Bare in mind the resistance will vary on the cable plugged in depending on the Amps it can supply.

[https://youtu.be/U3c4V8vMb6k?t=351 Video explaining the setup and demonstration.]

== Initial start-up and testing ==

=== Powering up and connecting to the web interface ===
'''The following is required'''
# A fully built ZombieVerter VCU
# Two wires for power
# 12V power supply
# Computer/tablet for accessing the web interface

'''How to access the web interface'''

# Provide stable 12V power to pins 55, 56 on the ZombieVerter
# The on-board LED light "acty" should be now flashing
# Using your computer, connect to the ZombieVerters WIFI access point. '''SSID: "inverter" or "zom_vcu"'''
# '''Password is: inverter123'''
# In a web browser navigate to: '''192.168.4.1'''
# The openinverter web interface should now load!

'''NOTE:''' Recent units have a new WiFi module that isn't automatically assigning an IP via DHCP. See [https://openinverter.org/forum/viewtopic.php?f=5&t=2001 this thread] for details, and if you can help resolve the issue. Until then, you need to manually assign an IP of 192.168.4.2 (anything other than 192.168.4.1 on the 192.168.4.0/24 subnet) to your device.

===Configuration===
<nowiki>*</nowiki>work in progress*

[[Zombieverter Parameters and Spot Values|full list and overview of ZombieVerter Parameters and Spot Values]]

==== Basic parameters and spot values ====

==== Throttle ====
You should see values '''pot''' change as the pedal is pressed.

* '''potmin''' should be set just above where your off-throttle position is
* '''potmax''' just below the value seen at maximum travel
* Same for '''pot2min''' and '''pot2max'''

The resulting in a 0-100 '''potnom''' value.

* '''throtmin''' is the minimum (most negative) allowed '''''potnom''''' at all times
* '''throtmax''' is the maximum (most positive) allowed '''''potnom''''' request in forward
* '''throtramp''' is how much '''potnom''' ramps up with the pedal pushed ('''potnom''' change per %/10ms)
* '''throtramprpm''' stops applying '''throtramp''' above a set motor rpm
* '''revlim''' is a rev limiter

==== Contactors ====
A set HV battery voltage value is required to run the precharge and main contactors.

The voltage is measured using the UDC value. which is supplied from the '''shuntType:'''

* '''ISA'''
* '''SBOX'''
* '''VAG'''
* '''LEAF'''

these voltage(UDC) levels are set with the following parameters:

* '''udcmin''' is the minimum battery voltage derate
* '''udclim''' is maximum battery voltage derate
* '''udcsw''' is Voltage point at which precharge is considered finished, and the main contactor will close.

'''Forward/Reverse'''

input options:

* '''switch'''
* '''button'''
* '''switchReversed'''
* '''buttomReversed'''

==== Inverter ====
''work in progress''

==== Charger ====

''work in progress''

==== Input Values ====
Check that din_break does not show "on", it must be off to allow potnom to be shown.
----
* Apply the '''Start''' 12V signal for a short time. The pre-charge relay should turn on, and the voltage available at the inverter and the U1 input of the ISA shunt should quickly rise. If the '''udc''' reading goes above '''udcsw''' within 5 seconds then the main contactor(s) should close. If all is well, '''invstat''' should now be "on", '''opmode''' should be "run".

''If you do not see a good value at udc, it may be that your external shunt is not connected properly or is not initialised.''

''If you do not see a good value at Invudc, it may be that the inverter is not powered, or the communication signals are not correctly wired.''

''if the status stays at "PRECHARGE" then you possibly didn't hold the start signal on for long enough!''

== Errors, Common issues ==

==== Input Values: ====

* "din_break" does not show "on", it must be off to allow potnom to be shown.
** check wiring setup
* UDC value updates during precharge.
** check that your UDC value source is configured correctly (shunt type, proper can bus, ect)
** check your contactor wiring.
*** some contactors are polarity sensitive
*** are they wired to be low side switched?
* check can H/ can L wiring
* is there too many devices sharing one can bus? (possible can id collision)
* check inverter power relay wiring
** is the inverter/charger/bms "ignition"/ "enable" pin driven via a zombie controlled relay?
** is the relay firing during preacharge?

==Software==

VCU boards from the webshop, '''''come pre-programed''''' and '''do not require any additional septs taken to work'''.

For programming a blank board see: [[zombiverter programing|ZombiVerter programing]]

For re-flashing a bricked board refer to the Troubleshooting section below.
==== Initializing an ISA Shunt: ====

# Wire the ISA shunt to 12V+ and canbus input.
# Under shunt can in the web interface, select the canbus the shunt is connected to
# Hit save parameters to flash.
# Under Comms in the web interface, select ISAMode option. By default its set to "Normal" (Off)
# Select "Init"
# Hit save parameters to flash
# Power cycle the vcu and shunt at same time (they should be on same 12V feed anyway).
# The shunt will initialize.
# Select ISAMode "normal"
# Save to flash again
# Reboot the VCU

The shunt should now be up and running.

If the shunt doesn't initialize correctly, separate the shunt and VCU power supply, and power cycle the VCU two or three seconds after the shunt power is cycled. This has fixed an initialize issue for a number of ISA shunts.

== Parameters ==
[[Zombieverter Parameters and Spot Values|page with ZombieVerter parameters and their value ranges, ZV pinmap etc.]]

Source: https://www.youtube.com/watch?v=wjlucUWX_lc

==Troubleshooting ==

===Serial Connection===
If you're having trouble connecting using the serial interface, note that the parameters are 115200 8-N-2, which is different from the conventional 115200 8-N-1.

=== Recovering the ZombieVerter from a failed update ===
If the ZombieVerter fails in the middle of a software update and the Web User Interface is reporting "firmware: null" it's possible you'll need to re-flash the firmware, and bootloader via an STLink.

I used a cheap STLink v2 clone without issue but it seems there is a mix of experiences with them.

# Firstly, download the bootloader from [https://github.com/jsphuebner/tumanako-inverter-fw-bootloader/releases here] and latest ZombieVerter firmware from [https://github.com/damienmaguire/Stm32-vcu/releases/ here] as .hex files. This ensures you don't need to know the address of the file and avoids user error when flashing via STLink
# Download STMCubeProgrammer from [https://www.st.com/en/development-tools/stm32cubeprog.html#get-software here] (other STM flashing softwares are available but the following instructions are based on what has worked for me).
# Upgrade the firmware on your STLink dongle using STMCubeProgrammer. I'm not sure if this is 100% necessary but seems prudent.
# Connect the Clock (SWclk), Gnd and Data (SWDio) of your STLink to the ZombieVerter test points. On the ZombieVerter Board, they are labelled C, G, D.
# Connect 12V and Gnd to the ZombieVerter main power pins and ensure your STMCubeprogrammer is able to connect to it. I also disconnected the wifi board just incase.
# Perform a "full chip erase", then reflash the latest bootloader and firmware hex files.
# Remove your STLink from the ZombieVerter, connect the wifi board and check connectivity.
# Begin ZombieVerter-ing.

=== ESP32 CanBus Web Interface ===
If the CanBus Web Interface is used it must be noted that the Node ID is hard coded to 3 (note Foccci default is 22)

==References==
<references />
[[Category:Inverter]]
[[Category:VCU]]
[[Category:ZombieVerter]]

ZombieVerter VCU

2025-09-17T06:05:48Z

Jason arnold: added note regarding current HW rev

[[File:Zombie model.png|thumb|614x614px|ZombieVerter VCU board (NOTE: V1.2 is preproduction, V1.a is the current latest hardware revision).]]
==== An open-source EV conversion VCU (vehicle control unit) for controlling salvaged EV components! ====
* '''[https://openinverter.org/forum/viewtopic.php?f=3&t=1277 Development thread]'''
* [https://github.com/damienmaguire/Stm32-vcu/releases '''latest stable software release''']
* '''[https://github.com/damienmaguire/Stm32-vcu GitHub repo]'''
* '''[https://www.evbmw.com/index.php/evbmw-webshop/vcu-boards/zombieverter-vcu-built fully built VCU boards]'''
* '''[https://www.evbmw.com/index.php/evbmw-webshop/vcu-boards/zombie-vcu partially-built VCU boards]'''
==Introduction ==
Modern EV conversion projects often look to reuse salvaged parts from wrecked vehicles, such as the motors, batteries and chargers.

The issue is that each of these components and manufacturers, use different methods of control and communication.

Developing controllers for these devices is complex, and time consuming and often require very dedicated communication protocols. Instead of making custom boards for every part that's been decoded, why not just make a general purpose VCU (vehicle control unit) with a verity of different types of inputs and outputs?

==== '''Introducing: the "ZombieVerter" VCU ''- a general purpose EV conversion VCU.''''' ====
With a large array of inputs/outputs, control logic, and a web interface for configuration and data logging. The ZombieVerter is a powerful, flexible and customizable VCU well suited for EV conversions.

It's also an open source project!

==== The ZombieVerter supports popular salvaged EV parts such as: ====

* Nissan Leaf components
* Mitsubishi Outlander hybrid components
* Toyota and Lexus hybrid components
* CHAdeMO and CCS DC fast charging
* and more!

==== The ZombieVerter features the following: ====

==== Hardware: ====

* On-board WiFi
* 3x high side PWM drivers
* 5x low side outputs
* 3x input pins (pull to ground only)
* 3x CANbus interfaces
* LIN bus
* sync serial interface
* OBD-II interface
* etc.

==== Software: ====

* Web based user interface
* Contactor control
* Charger control
* Charge timer
* Motor (inverter) control
* Heater control
* Water pump control
* Coolant fan control
* Throttle mapping
* Motor regen
* Cruise control (?)
* BMS limits
* IVT shunt initialization
* Data logging and graphing
* etc.
=== Currently supported OEM hardware: ===
<nowiki>*</nowiki>This list is always growing and changing, and not everything is verified working

==== Motors/Drive units: ====

* [[Nissan leaf motors|Nissan Leaf Gen1/2/3 inverter/motor via CAN]]
* [[Lexus GS450h Drivetrain|Lexus GS450h inverter / L110 gearbox via sync serial]]
* Lexus GS300h inverter / L210 gearbox via sync serial
* Toyota Prius/Yaris/Auris Gen 3 inverters via sync serial

* [[:Category:Mitsubishi|Mitsubishi Outlander motors/inverter]]
* openinverter controler

===== Chargers/DCDCs: =====
* [[Nissan leaf pdm|Nissan Leaf PDM (Charger and DCDC)]] Gen1,2 & 3
* [[Mitsubishi Outlander DCDC OBC|Mitsubishi Outlander OBC (charger/DCDC)]]
* [[Tesla Model S/X DC/DC Converter|tesla model S dcdc]]
* [[BMW I3 Fast Charging LIM Module|CCS DC fast charge via BMW i3 LIM]] - type 2 + type 1
* [[Chademo with Zombieverter|Chademo DC fast charging]]
* [[Foccci|Foccci CCS faster charger controller]]
* [https://citini.com/product/evs-charge-port-controller/ EVS-Charge Port Controller]
* Elcon charger

===== Heaters: =====

*[[Volkswagen Heater|VAG/VW PTC water heater via LIN bus]]
*[[VAG PTC Air Heater|VAG/VW cabin heater via LIN bus]]

* [[Chevrolet Volt Water Heater|Opel Ampera / Chevy Volt 6.5kW cabin heater]]
* [[Mitsubishi Outlander Water Heater|Mitsubishi outlander hybrid water heater]]

===== BMS: =====
* [[Nissan Leaf BMS|Nissan leaf BMS]]/battery pack
* [[Renault Kangoo 36|kangoo bms]]
*orion bms
*[https://github.com/Tom-evnut/SimpBMS SimpBMS]
*[[Isabellenhütte Heusler|ISA shunt]]
*[[BMW Hybrid Battery Pack#S-Box|BMW SBOX]]
*VW EBOX

===== Cars(for canbus control over dash, etc): =====
* 1998-2005 BMW 3-series (E46) CAN support
* 1996-2003 BMW 5-series (E39) CAN support
* 2001-2008 BMW 7-series (E65) CAN Support
* BMW E9x CAN support
* Mid-2000s VAG CAN support
* Subaru CAN support
== Assembling the VCU ==
Looking to build a ZombieVerter VCU yourself or the kit is missing hardware?

* [[Zombiverter hardware]] page for additional build instructions

* [https://github.com/damienmaguire/Stm32-vcu Github with PCB, schematic, pin-outs, etc]

''The enclosure and header are required if you did not order a [https://www.evbmw.com/index.php/evbmw-webshop/vcu-boards/zombieverter-vcu-built '''fully built board''']''

VCU boards from the webshop, '''''come pre-programmed''''' and '''do not require any additional steps taken to work'''.

For programming a blank board see: [[zombieverter programing|ZombieVerter programming]]
===The enclosure kit options:===

# [https://www.aliexpress.com/item/32857771975.html?spm=a2g0s.9042311.0.0.39f24c4dWOmGPE Enclosure Kit with Header, connector and pins]<ref>https://www.aliexpress.com/item/32857771975.html?spm=a2g0s.9042311.0.0.39f24c4dWOmGPE (Backup: [https://web.archive.org/web/20220524004318/https://www.aliexpress.com/item/32857771975.html Web Archive])</ref>
#[https://www.aliexpress.com/item/32822692950.html Connector and pins]<ref>https://de.aliexpress.com/item/32822692950.html (Backup: [https://web.archive.org/web/20221119203700/https://www.aliexpress.us/item/2251832636378198.html?gatewayAdapt=glo2usa4itemAdapt&_randl_shipto=US Web Archive])</ref>
#[https://www.aliexpress.com/item/1005003512474442.html Pre-wired connector] <ref>https://www.aliexpress.com/item/1005003512474442.html (Backup: [http://web.archive.org/web/20221120105651/https://www.aliexpress.us/item/3256803326159690.html?gatewayAdapt=glo2usa4itemAdapt&_randl_shipto=US Web Archive])</ref>

The original connectors are from Aptiv (Delphi):

* [https://www.aptiv.com/en/solutions/connection-systems/catalog/item?id=13669859_en Aptiv 56-pin connector]
* [https://www.aptiv.com/en/solutions/connection-systems/catalog/item?id=33511394_en Aptiv 56-pin header]
* [https://www.tti.com/content/ttiinc/en/apps/part-detail.html?partsNumber=210S048&mfgShortname=FCA&productId=161404611 Removal tool for connector terminals: Manufacturer: Aptiv (formerly Delphi)] Part Number: 210S048
=== Videos on assembly, powering up, updating, etc: ===
https://www.youtube.com/watch?v=geZuIbGHh30&list=PLh-aHjjWGgLVCsAqaCL6_jmn_QqhVlRiG

https://www.youtube.com/watch?v=_JRa_uFyVkY&list=PLh-aHjjWGgLUWaetAmShkv6gmvk7vLaHd
== Wiring ==
[[File:ZombieVerter VCU V1 cable side pinout2.jpg|thumb|alt=|VCU pinout diagram |513x513px]]Each device requires different wiring setups, settings and power requirements.

<nowiki>*</nowiki>cross referencing OEM wiring diagrams is highly recommended

'''Wiring the ZombieVerter with:'''

* [[GS450H with zombieverter|GS450H with ZombieVerter]]
* [[Leaf stack with zombiverter|Leaf stack with ZombiVerter]]
* [[Tesla SDU with Zombieverter|Tesla SDU with ZombieVerter]]
* [[Chademo with Zombieverter]]

=== Power wiring ===
The ZombieVerter requires a permanent 12V supply. This is so it can manage charging, timers, and monitor systems when the car is at rest.

The average power draw, at idle, is 150 mA.

* Pin 55 to 12V- ground
* Pin 56 to 12V+ positive

The ZombieVerter controls power/"ignition" signals to other devices (inverters, chargers, and DCDC converters), powering those devices when required. This is done by triggering an external 12V relay. '''''ZombieVerter controls the external relay using low-side switching'', meaning that it pulls the ground pin of the relay to ground.'''

* [[File:Gernice-zombie.png|thumb|583x583px|general zombie and battery box wiring]]Pin 32 to ground pin on a 12V relay
* Relay positive pin to 12V+
* One of the relays switch pin to 12V+

This effectively provides a switched 12V supply, controlled by the ZombieVerter.

Used to switch "enable" mode to devices via:

* Leaf inverter enable pin
* Leaf PDM enable pin
* Mitsubisihi OBC enable pin

=== Contactor wiring ===
The Zombieveter manages the Negative, Positive and PreCharge contactors in an EV conversion.

This is done based off a series of voltage measurements (UDC), this voltage value (UDC) can be supplied from a variety of sources:

* ISA IVT shunt
* Nissan leaf inverter
* BMW S-BOX
* etc.

''Without a proper UDC measurement, the ZombieVerter '''will fail precharge and never go into run mode.'''''

'''The contactor control pins on the ZombieVerter are ''low-side switching'', meaning that they pull to ground.'''

The positive leads from the contactors need to be connected to 12V+ and the ground leads to:

* Pin 31 for the negative contactor
* Pin 33 for the positive contactor
* Pin 34 for the pre-charge contactor
=== Throttle pedal wiring ===
The ZombieVerter supports dual-channel throttle. This redundancy is for safety in case one channel fails or drops out. It's highly recommended to use dual-channel throttle. Single-channel is an option.

Connect the following to the ZombieVerter pins:

* Pin 45 to throttle grounds
* Pin 46 to throttle channel 2
* Pin 47 to throttle channel 1
* Pin 48 to throttle positives

=== Start, Run, and Direction wiring ===
The ZombieVerter requires 2 inputs to get into "drive" mode. '''These pins need to be ''pulled high'' (connected to 12V +)'''

* Pin 15 to "on" switched input (key switched to "on")
* Pin 52 to "start" momentary input (momentary key switched "ignition")

==== Forward and Reverse ====
These pins need to be ''pulled high'' (connected to 12V +)

* Pin 53 reverse
* Pin 54 forward

==== Brake signal ====

* Pin 49 need to be ''pulled high'' (connected to 12V +) when brake is pressed

=== Input/output pins ===
The ZombieVerter has a number of selectable input/output pins that can be used for a number of functions. These pins are:

Low side Outputs.

*GP Out 3
*GP Out 2
* Neg Contactor switch/GP Out 1
*Trans SL1- (If not using the GS450H)
*Trans SL2- (If not using the GS450H)

'''*Low side output connect to ground when activated.'''

The low side outputs in Zombie are ideal for switching relays, such as for coolant pumps.

High side PWM.

*PWM 3
*PWM 2
*PWM 1
*Pump PWM - Limited to GS450 Oil pump pwm or tacho pwm output

These are high side 12V outputs, usually for controlling gauges or auxiliary items than need a pwm signals.

'''*not suitable for controlling relays.'''

Ground Input pins

These pins pull down to ground only. '''Do not connect any voltage to these pins.'''

PB1

PB2

PB3

=== Pin functions: ===
''Note: While the web interface will allow you to select input pins or output pins, some will not actually work.''

''example: a input switch wired but set to negContactor''
{| class="wikitable"
|+
!Pin
!IN/OUT/PWM
!Function
|-
|ChaDemoAIw
|'''OUTPUT'''
|activates when Chademo charger handshake initiates
|-
|OBCEnable
|'''OUTPUT'''
|activates as part of the ExtCharger module
|-
|HeaterEnable
|'''OUTPUT'''
|activates only in run mode and when coolant pump is on*
|-
|RunIndication
|'''OUTPUT'''
|activates when zombie is in run mode
|-
|WarnIndication
|'''OUTPUT'''
|activates when a error occurs with the ZombieVerter
|-
|CoolantPump
|'''OUTPUT'''
|activates during precharge, usually used for coolant pumps
|-
|NegContactor
|'''OUTPUT'''
|activates when the negative contactor needs to be closed. ie precharge, run, charge mode, etc
|-
|BrakeLight
|'''OUTPUT'''
|activates when a set brake light on threshold value is met
|-
|ReverseLight
|'''OUTPUT'''
|activates when reverse direction is selected
|-
|CoolingFan
|'''OUTPUT'''
|activates when FanTemp setpoint is reached
|-
|HVActive
|'''OUTPUT'''
|activates when contactors are closed and VCU is in run or charge mode
|-
|BrakeVacPump
|'''DIGITAL OUTPUT'''
|activates when BrakeVacSensor threshold value is met
|-
|CpSpoof
|'''PWM OUTPUT'''
|used to spoof CP signal to OBC when using a charging interface such as FOCCCI or I3LIM
|-
|GS450Hpump
|'''PWM OUTPUT'''
|used to run GS450H oil pump
|-
|HeatReq
|'''DIGITAL INPUT'''
|
|-
|HVRequest
|'''DIGITAL INPUT'''
|NOT FUNCTIONING
|-
|DCFCRequest
|'''DIGITAL INPUT'''
|Chademo Charge Interface enable contactors to charge
|-
|ProxPilot
|'''ANALOGUE INPUT'''
|detects when charge cable is plugged in
|-
|BrakeVacSensor
|'''ANALOGUE INPUT'''
|vacuum sensor input, use for triggering BrakeVacPump '''DIGITAL OUTPUT'''
|-
|PWMTim3
|
|
|}

==== Proximity Pilot====
This analogue input used to detect a charging cable is plugged in.
[[File:ZombiePP.png|none|thumb]]
A resistor to the 5v needs to be connected to the analogue in pin, 330 ohms in the spec, and R5 needs to be another resistor between analogue in pin and ground. Type 1 connectors should be a 2.7k ohm resistor and type 2 should be 4.7k ohm. Note the charging port may already have this resistor installed.

Open up the Zombie UI and choose ProxPilot for the function of the analogue in pin. Then start plotting PPVal and then plug in, you can then use this to select your PPThreshold. Bare in mind the resistance will vary on the cable plugged in depending on the Amps it can supply.

[https://youtu.be/U3c4V8vMb6k?t=351 Video explaining the setup and demonstration.]
== Initial start-up and testing ==

=== Powering up and connecting to the web interface ===

==== '''The following is required''' ====
# A fully built ZombieVerter VCU
# Two wires for power
# 12V power supply
# Computer/tablet for accessing the web interface

'''How to access the web interface'''

# Provide stable 12V power to pins 55, 56 on the ZombieVerter
# The on-board LED light "acty" should be now flashing
# Using your computer, connect to the ZombieVerters WIFI access point. '''SSID: "inverter" or "zom_vcu"'''
# '''Password is: inverter123'''
# In a web browser navigate to: '''192.168.4.1'''
# The openinverter web interface should now load!

'''NOTE:''' Recent units have a new WiFi module that isn't automatically assigning an IP via DHCP. See [https://openinverter.org/forum/viewtopic.php?f=5&t=2001 this thread] for details, and if you can help resolve the issue. Until then, you need to manually assign an IP of 192.168.4.2 (anything other than 192.168.4.1 on the 192.168.4.0/24 subnet) to your device.

===Configuration===
<nowiki>*</nowiki>work in progress*

[[Zombieverter Parameters and Spot Values|full list and overview of ZombieVerter Parameters and Spot Values]]

==== Basic parameters and spot values ====

==== Throttle ====
You should see values '''pot''' change as the pedal is pressed.

* '''potmin''' should be set just above where your off-throttle position is
* '''potmax''' just below the value seen at maximum travel
* Same for '''pot2min''' and '''pot2max'''

The resulting in a 0-100 '''potnom''' value.

* '''throtmin''' is the minimum (most negative) allowed '''''potnom''''' at all times
* '''throtmax''' is the maximum (most positive) allowed '''''potnom''''' request in forward
* '''throtramp''' is how much '''potnom''' ramps up with the pedal pushed ('''potnom''' change per %/10ms)
* '''throtramprpm''' stops applying '''throtramp''' above a set motor rpm
* '''revlim''' is a rev limiter

==== Contactors ====
A set HV battery voltage value is required to run the precharge and main contactors.

The voltage is measured using the UDC value. which is supplied from the '''shuntType:'''

* '''ISA'''
* '''SBOX'''
* '''VAG'''
* '''LEAF'''

these voltage(UDC) levels are set with the following parameters:

* '''udcmin''' is the minimum battery voltage derate
* '''udclim''' is maximum battery voltage derate
* '''udcsw''' is Voltage point at which precharge is considered finished, and the main contactor will close.

'''Forward/Reverse'''

input options:

* '''switch'''
* '''button'''
* '''switchReversed'''
* '''buttomReversed'''

==== Inverter ====
''work in progress''

==== Charger ====

''work in progress''

==== Input Values ====
Check that din_break does not show "on", it must be off to allow potnom to be shown.
----
* Apply the '''Start''' 12V signal for a short time. The pre-charge relay should turn on, and the voltage available at the inverter and the U1 input of the ISA shunt should quickly rise. If the '''udc''' reading goes above '''udcsw''' within 5 seconds then the main contactor(s) should close. If all is well, '''invstat''' should now be "on", '''opmode''' should be "run".

''If you do not see a good value at udc, it may be that your external shunt is not connected properly or is not initialised.''

''If you do not see a good value at Invudc, it may be that the inverter is not powered, or the communication signals are not correctly wired.''

''if the status stays at "PRECHARGE" then you possibly didn't hold the start signal on for long enough!''

== Errors, Common issues ==

==== Input Values: ====

* "din_break" does not show "on", it must be off to allow potnom to be shown.
** check wiring setup
* UDC value updates during precharge.
** check that your UDC value source is configured correctly (shunt type, proper can bus, ect)
** check your contactor wiring.
*** some contactors are polarity sensitive
*** are they wired to be low side switched?
* check can H/ can L wiring
* is there too many devices sharing one can bus? (possible can id collision)
* check inverter power relay wiring
** is the inverter/charger/bms "ignition"/ "enable" pin driven via a zombie controlled relay?
** is the relay firing during preacharge?

==Software==

VCU boards from the webshop, '''''come pre-programed''''' and '''do not require any additional septs taken to work'''.

For programming a blank board see: [[zombiverter programing|ZombiVerter programing]]

For re-flashing a bricked board refer to the Troubleshooting section below.
==== Initializing an ISA Shunt: ====

# Wire the ISA shunt to 12V+ and canbus input.
# Under shunt can in the web interface, select the canbus the shunt is connected to
# Hit save parameters to flash.
# Under Comms in the web interface, select ISAMode option. By default its set to "Normal" (Off)
# Select "Init"
# Hit save parameters to flash
# Power cycle the vcu and shunt at same time (they should be on same 12V feed anyway).
# The shunt will initialize.
# Select ISAMode "normal"
# Save to flash again
# Reboot the VCU

The shunt should now be up and running.

If the shunt doesn't initialize correctly, separate the shunt and VCU power supply, and power cycle the VCU two or three seconds after the shunt power is cycled. This has fixed an initialize issue for a number of ISA shunts.

== Parameters ==
[[Zombieverter Parameters and Spot Values|page with ZombieVerter parameters and their value ranges, ZV pinmap etc.]]

Source: https://www.youtube.com/watch?v=wjlucUWX_lc

==Troubleshooting ==

===Serial Connection===
If you're having trouble connecting using the serial interface, note that the parameters are 115200 8-N-2, which is different from the conventional 115200 8-N-1.

=== Recovering the ZombieVerter from a failed update ===
If the ZombieVerter fails in the middle of a software update and the Web User Interface is reporting "firmware: null" it's possible you'll need to re-flash the firmware, and bootloader via an STLink.

I used a cheap STLink v2 clone without issue but it seems there is a mix of experiences with them.

# Firstly, download the bootloader from [https://github.com/jsphuebner/tumanako-inverter-fw-bootloader/releases here] and latest ZombieVerter firmware from [https://github.com/damienmaguire/Stm32-vcu/releases/ here] as .hex files. This ensures you don't need to know the address of the file and avoids user error when flashing via STLink
# Download STMCubeProgrammer from [https://www.st.com/en/development-tools/stm32cubeprog.html#get-software here] (other STM flashing softwares are available but the following instructions are based on what has worked for me).
# Upgrade the firmware on your STLink dongle using STMCubeProgrammer. I'm not sure if this is 100% necessary but seems prudent.
# Connect the Clock (SWclk), Gnd and Data (SWDio) of your STLink to the ZombieVerter test points. On the ZombieVerter Board, they are labelled C, G, D.
# Connect 12V and Gnd to the ZombieVerter main power pins and ensure your STMCubeprogrammer is able to connect to it. I also disconnected the wifi board just incase.
# Perform a "full chip erase", then reflash the latest bootloader and firmware hex files.
# Remove your STLink from the ZombieVerter, connect the wifi board and check connectivity.
# Begin ZombieVerter-ing.

=== ESP32 CanBus Web Interface ===
If the CanBus Web Interface is used it must be noted that the Node ID is hard coded to 3 (note Foccci default is 22)

==References==
<references />
[[Category:Inverter]]
[[Category:VCU]]
[[Category:ZombieVerter]]

Olimex MOD-WIFI-ESP8266

2025-02-20T12:41:33Z

Jason arnold: /* Flashing Process Overview */

The Olimex MOD-WIFI-ESP8266 WiFi expansion module is commonly used to provide WiFi connectivity and a web interface for several inverter controllers including those in the the OpenInverter ecosystem.

It is not just a WiFi chip - it actually hosts a web server that you can connect to in order to set parameters and monitor behaviour. The module communicates with OpenInverter controllers a UEXT header connector.

When used in the OpenInverter ecosystem (including ZombieVerter), this module is typically flashed with the [ESP8266-web-interface](https://github.com/jsphuebner/esp8266-web-interface) software. You can refer to the README of that code repository for up to date guidance on how to use the software and how to flash it onto an Olimex module.

Below we include an example of how you might want to flash a module.

=== Flashing Process Overview ===
[[File:Esp8266-flash.png|thumb]]By default, when the module powers up it will be in FLASH boot mode (counterintuitively, this means the device will run code in its flash memory, not that the device is ready to be flashed). To flash code onto the module, it must be set instead into in UART boot mode. It's important to note, as the name implies, "boot modes" are set at boot (i.e. when the device is powered on), so they cannot be changed while when the device is running. To set the UART boot mode, hold the small pushbutton on the top side of the module down while you plug it in, this holds GPIO0 to ground and is the same process as the much-hated setting modes via solder blobs, but without the hassle. Unlike the solder blobs, which holds GPIO0 low until the blob is moved, you don't have to keep the pushbutton held down, so after plugging in the device with the button pushed, you can release it.

==== Quick Method ====
''*This may be deprecated as the bin linked below hasn't been updated in some time*''

Get ESP Tool https://raw.githubusercontent.com/espressif/esptool/master/esptool.py

Get single binary which flashes both the firmware and SPIFFS contents: https://openinverter.org/forum/download/file.php?id=9167

Flash binary using the following command:

<code>python esptool.py --port COM<your-port-here> --baud 115200 write_flash 0x0 FSBrowser.ino.modwifi.bin</code>

==== Full Method ====
https://openinverter.org/forum/viewtopic.php?p=4928#p4928

These steps have proved successful on Windows 10 using Arduino IDE v1.8.13 and version 0.5.0 of the ESP8266 Filesystem Uploader.

You'll also need a Micro-USB cable capable of data transfer - some of the cheaper ones are only used for charging.

1. Download the Arduino IDE and install it to PC

2. Buy a Wemos D1 mini ESP8266 board with FTDI and get CH340 driver from https://www.wemos.cc/en/latest/d1/d1_mini.html (or use Olimex)

3. Install the CH340 driver on your computer. When the installer opens run the uninstall option first to remove any previous versions of the driver. Then perform the installation.

4. Inside Arduino IDE install ESP8266

- open the Preferences window

- enter https://arduino.esp8266.com/stable/package_esp8266com_index.json into the Additional Board Manager URLs

- open Boards Manager from Tools > Board menu and install esp8266 platform. I select LOLIN D1 R2 mini board, settings (tools menu) are in the pic
[[File:Settings.jpg|alt=Arduino IDE settings for Wemos D1 mini board|thumb|Arduino IDE settings for Wemos D1 mini board]]

5. Install ESP8266 Filesystem Uploader

- Download https://github.com/esp8266/arduino-esp8266fs-plugin/releases python support files

- extract file to Arduino IDE tools folder like you see here https://randomnerdtutorials.com/install-esp8266-filesystem-uploader-arduino-ide/

- restart Arduino for changes to come into effect

6. Download Johannes Web interface code here: https://github.com/jsphuebner/esp8266-web-interface

- make a note of the name of the .ino file then rename the enclosing folder with the same name (ie if the .ino file is ‘eps8266-web-interface.ino’ rename the enclosing folder ‘eps8266-web-interface’)

- move the renamed folder to the Arduino folder on your hard disc. This is usually inside your documents folder (eg …\Documents \ Arduino \ eps8266-web-interface )

7. Open Johannes Web interface code in the Ardunio IDE by double clicking the .ino file. The following edit may be needed:

- at about line 14 of the code (not the comments) there’s a line that should read "bool fastuartavailable = false;" if the value is set to true change it to false

8. Connect board to USB and select correct COM port and rest of settings

- if you used a new board you have to select "erase flash: sketch + wifi settings" so the board will erase its password

- click upload and wait for interface to reset the board

- select tools/ESP8266 sketch data upload and wait for the board to reset

- connect to the board’s WiFi network then go to <nowiki>http://192.168.4.1/</nowiki> to see the web interface

- remember set up your own wifi name and password for the interface

==== Troubleshooting ====

===== WiFi doesn't show up =====
- in Arduino studio Tools -> Serial Monitor gives debug info of the chip. If the Serial Monitor says "<code>Unknown command sequence"</code> you need to change the TTL

- if GPIO0 is not resoldered, the chip is in programming mode and will not boot from the flash code

===== FileNotFound Error in WebInterface =====

Upload the files from the repository <nowiki>https://github.com/jsphuebner/esp8266-web-interface</nowiki> with below command:<blockquote><syntaxhighlight lang="bash">
#!/bin/bash
IP=192.168.4.1
echo $IP
curl -F 'data=@README.md' http://$IP/edit
curl -F 'data=@ajax-loader.gif' http://$IP/edit
curl -F 'data=@chart.min.js.gz' http://$IP/edit
curl -F 'data=@chartjs-annotation.min.js.gz' http://$IP/edit
curl -F 'data=@gauge.min.js.gz' http://$IP/edit
curl -F 'data=@gauges.html' http://$IP/edit
curl -F 'data=@gauges.js' http://$IP/edit
curl -F 'data=@index.html' http://$IP/edit
curl -F 'data=@index.js' http://$IP/edit
curl -F 'data=@inverter.js' http://$IP/edit
curl -F 'data=@jquery.core.min.js.gz' http://$IP/edit
curl -F 'data=@jquery.knob.min.js.gz' http://$IP/edit
# curl -F 'data=@log.htm' http://$IP/edit
curl -F 'data=@log.html' http://$IP/edit
curl -F 'data=@log.js' http://$IP/edit
curl -F 'data=@refresh.png' http://$IP/edit
curl -F 'data=@remote.html' http://$IP/edit
curl -F 'data=@style.css' http://$IP/edit
curl -F 'data=@syncofs.html' http://$IP/edit
curl -F 'data=@upload.sh' http://$IP/edit
curl -F 'data=@wifi-updated.html' http://$IP/edit
curl -F 'data=@wifi.html' http://$IP/edit
</syntaxhighlight>If the above commands don't work, try removing the single apostrophes around the filename, there seems to be some discrepancies in Curl formatting between Linux and the version included in Windows 10 command prompt.

Example: curl -F data=@wifi.html <nowiki>http://$IP/edit</nowiki></blockquote>Replace $IP with 192.168.4.1

=== Flashing Process for GS450H ===

==== Part 1: Software and IDE. ====
<nowiki>https://www.arduino.cc/en/software</nowiki>

I've tested this on 1.8.13 so go ahead and grab that and install.

Next you will need to add the ESP8266 to your boards manager.

Tutorial here : https://randomnerdtutorials.com/how-to-install-esp8266-board-arduino-ide/

Go ahead and do that.

Download the WiFi package from my Github :

https://github.com/damienmaguire/Lexus-GS450H-Inverter-Controller/tree/master/WiFi

Copy it to your Arduino sketch directory. Close and reopen Arduino, go to file, sketchbook and it should show up.

Go ahead and open it.

Now you need the correct libraries which is where the fun starts as they are a hot mess in Arduino these days.

I uploaded mine to the repo :

https://github.com/damienmaguire/Lexus-GS450H-Inverter-Controller/tree/master/Software/Libraries

Grab those and unzip both files to your /Arduino/libraries directory.

Next up go to tools and setup your board exactly as shown in the picture.

Close and reopen Arduino then hit the tick box to compile. If you did everything right it will just compile.

==== Part 2: programming method. ====
You will need a 3v3 level FTDI cable:

https://www.mouser.ie/ProductDetail/FTDI/TTL-232R-3V3/?qs=Xb8IjHhkxj627GFcejHp0Q==

Yes you can use others, no I have no idea if they will work. This is the one I use.

Wire it as per the the attached diagram.

Now, to program the module you need to desolder the GPIO0 jumper and move it to the "0" position.

Back to tools and select your COM port.

Click the upload icon (right facing arrow).

When upload is done, unplug and replug the WiFi module from the FTDI cable but do not unplug the USB end from the computer.

Back to tools and click "esp8266 sketch data upload".

when done remove the module and resolder the GPIO0 jumper back to position "1".

Congratulations, it's now programmed.

==== Precompiled binaries (similar to step 3 shortcut in the tutorial above) ====
attached the compiled binaries for use with the WEMOS D1 Mini, including the SPIFFS filesystem .bin

the SSID is "GS450H-VCU" and the WiFi password is ''`inverter123`''

https://openinverter.org/forum/download/file.php?id=9051

https://openinverter.org/forum/download/file.php?id=9050

=== Common Issues ===

[[File:ESP8266 communication with DuPont jump leads and without.png|thumb|If experiencing connection issues, try different cables to rule out bad connectors ( apparently common with recent Olimex)]]
* The settings & partition size in Arduino Studio are easy to get wrong. [https://openinverter.org/forum/viewtopic.php?p=29523#p29523]
* If you get any of: 1) incomplete responses via HTTP 2) patchy WiFi on a logic board 3) parameters from logic board not loading in web interface; you can try powering the ESP8266 from a different source, or connect it via DuPont leads to rule out connector & plug issues (see photographs).
* If you are all out of luck, there are alternative boards discussed here [https://openinverter.org/forum/viewtopic.php?t=2299]
[[Category:OpenInverter]] [[Category:ESP8266]]

Olimex MOD-WIFI-ESP8266

2025-02-20T12:37:06Z

Jason arnold: rewrote overview to omit solder jumper references and explained how to flash using jumper pushbutton instead

The Olimex MOD-WIFI-ESP8266 WiFi expansion module is commonly used to provide WiFi connectivity and a web interface for several inverter controllers including those in the the OpenInverter ecosystem.

It is not just a WiFi chip - it actually hosts a web server that you can connect to in order to set parameters and monitor behaviour. The module communicates with OpenInverter controllers a UEXT header connector.

When used in the OpenInverter ecosystem (including ZombieVerter), this module is typically flashed with the [ESP8266-web-interface](https://github.com/jsphuebner/esp8266-web-interface) software. You can refer to the README of that code repository for up to date guidance on how to use the software and how to flash it onto an Olimex module.

Below we include an example of how you might want to flash a module.

=== Flashing Process Overview ===
[[File:Esp8266-flash.png|thumb]]By default, when the module powers up it will be in FLASH boot mode (counterintuitively, this means the device will run code in its flash memory, not that the device is ready to be flashed). To flash code onto the module, it must be set instead into in UART boot mode. It's important to note, as the name implies, "boot modes" are set at boot (i.e. when the device is powered on), so they cannot be changed while when the device is running. To set the UART boot mode, hold the small pushbutton on the top side of the module down while you plug it in, this holds GPIO0 to ground and is the same process as the much-hated setting modes via solder blobs, but without the hassle. Unlike the solder blobs, which holds GPIO0 low until the blob is moved, you don't have to keep the pushbutton held down, so after plugging in the device with the button pushed, you can release it.

==== Quick Method ====

==== ''*This may be deprecated as the bin linked below hasn't been updated in some time*'' ====
Get ESP Tool https://raw.githubusercontent.com/espressif/esptool/master/esptool.py

Get single binary which flashes both the firmware and SPIFFS contents: https://openinverter.org/forum/download/file.php?id=9167

Flash binary using the following command:

<code>python esptool.py --port COM<your-port-here> --baud 115200 write_flash 0x0 FSBrowser.ino.modwifi.bin</code>

====== Full Method ======
https://openinverter.org/forum/viewtopic.php?p=4928#p4928

These steps have proved successful on Windows 10 using Arduino IDE v1.8.13 and version 0.5.0 of the ESP8266 Filesystem Uploader.

You'll also need a Micro-USB cable capable of data transfer - some of the cheaper ones are only used for charging.

1. Download the Arduino IDE and install it to PC

2. Buy a Wemos D1 mini ESP8266 board with FTDI and get CH340 driver from https://www.wemos.cc/en/latest/d1/d1_mini.html (or use Olimex)

3. Install the CH340 driver on your computer. When the installer opens run the uninstall option first to remove any previous versions of the driver. Then perform the installation.

4. Inside Arduino IDE install ESP8266

- open the Preferences window

- enter https://arduino.esp8266.com/stable/package_esp8266com_index.json into the Additional Board Manager URLs

- open Boards Manager from Tools > Board menu and install esp8266 platform. I select LOLIN D1 R2 mini board, settings (tools menu) are in the pic
[[File:Settings.jpg|alt=Arduino IDE settings for Wemos D1 mini board|thumb|Arduino IDE settings for Wemos D1 mini board]]

5. Install ESP8266 Filesystem Uploader

- Download https://github.com/esp8266/arduino-esp8266fs-plugin/releases python support files

- extract file to Arduino IDE tools folder like you see here https://randomnerdtutorials.com/install-esp8266-filesystem-uploader-arduino-ide/

- restart Arduino for changes to come into effect

6. Download Johannes Web interface code here: https://github.com/jsphuebner/esp8266-web-interface

- make a note of the name of the .ino file then rename the enclosing folder with the same name (ie if the .ino file is ‘eps8266-web-interface.ino’ rename the enclosing folder ‘eps8266-web-interface’)

- move the renamed folder to the Arduino folder on your hard disc. This is usually inside your documents folder (eg …\Documents \ Arduino \ eps8266-web-interface )

7. Open Johannes Web interface code in the Ardunio IDE by double clicking the .ino file. The following edit may be needed:

- at about line 14 of the code (not the comments) there’s a line that should read "bool fastuartavailable = false;" if the value is set to true change it to false

8. Connect board to USB and select correct COM port and rest of settings

- if you used a new board you have to select "erase flash: sketch + wifi settings" so the board will erase its password

- click upload and wait for interface to reset the board

- select tools/ESP8266 sketch data upload and wait for the board to reset

- connect to the board’s WiFi network then go to <nowiki>http://192.168.4.1/</nowiki> to see the web interface

- remember set up your own wifi name and password for the interface

====== WiFi doesn't show up ======
- in Arduino studio Tools -> Serial Monitor gives debug info of the chip. If the Serial Monitor says "<code>Unknown command sequence"</code> you need to change the TTL

- if GPIO0 is not resoldered, the chip is in programming mode and will not boot from the flash code

====== FileNotFound Error in WebInterface ======
Upload the files from the repository <nowiki>https://github.com/jsphuebner/esp8266-web-interface</nowiki> with below command:<blockquote><syntaxhighlight lang="bash">
#!/bin/bash
IP=192.168.4.1
echo $IP
curl -F 'data=@README.md' http://$IP/edit
curl -F 'data=@ajax-loader.gif' http://$IP/edit
curl -F 'data=@chart.min.js.gz' http://$IP/edit
curl -F 'data=@chartjs-annotation.min.js.gz' http://$IP/edit
curl -F 'data=@gauge.min.js.gz' http://$IP/edit
curl -F 'data=@gauges.html' http://$IP/edit
curl -F 'data=@gauges.js' http://$IP/edit
curl -F 'data=@index.html' http://$IP/edit
curl -F 'data=@index.js' http://$IP/edit
curl -F 'data=@inverter.js' http://$IP/edit
curl -F 'data=@jquery.core.min.js.gz' http://$IP/edit
curl -F 'data=@jquery.knob.min.js.gz' http://$IP/edit
# curl -F 'data=@log.htm' http://$IP/edit
curl -F 'data=@log.html' http://$IP/edit
curl -F 'data=@log.js' http://$IP/edit
curl -F 'data=@refresh.png' http://$IP/edit
curl -F 'data=@remote.html' http://$IP/edit
curl -F 'data=@style.css' http://$IP/edit
curl -F 'data=@syncofs.html' http://$IP/edit
curl -F 'data=@upload.sh' http://$IP/edit
curl -F 'data=@wifi-updated.html' http://$IP/edit
curl -F 'data=@wifi.html' http://$IP/edit
</syntaxhighlight>If the above commands don't work, try removing the single apostrophes around the filename, there seems to be some discrepancies in Curl formatting between Linux and the version included in Windows 10 command prompt.

Example: curl -F data=@wifi.html <nowiki>http://$IP/edit</nowiki></blockquote>Replace $IP with 192.168.4.1

=== Flashing Process for GS450H ===

====== Part 1 : Software and IDE. ======
<nowiki>https://www.arduino.cc/en/software</nowiki>

I've tested this on 1.8.13 so go ahead and grab that and install.

Next you will need to add the ESP8266 to your boards manager.

Tutorial here : https://randomnerdtutorials.com/how-to-install-esp8266-board-arduino-ide/

Go ahead and do that.

Download the WiFi package from my Github :

https://github.com/damienmaguire/Lexus-GS450H-Inverter-Controller/tree/master/WiFi

Copy it to your Arduino sketch directory. Close and reopen Arduino, go to file, sketchbook and it should show up.

Go ahead and open it.

Now you need the correct libraries which is where the fun starts as they are a hot mess in Arduino these days.

I uploaded mine to the repo :

https://github.com/damienmaguire/Lexus-GS450H-Inverter-Controller/tree/master/Software/Libraries

Grab those and unzip both files to your /Arduino/libraries directory.

Next up go to tools and setup your board exactly as shown in the picture.

Close and reopen Arduino then hit the tick box to compile. If you did everything right it will just compile.

====== Part 2 : programming method. ======
You will need a 3v3 level FTDI cable :

https://www.mouser.ie/ProductDetail/FTDI/TTL-232R-3V3/?qs=Xb8IjHhkxj627GFcejHp0Q==

Yes you can use others, no I have no idea if they will work. This is the one I use.

Wire it as per the the attached diagram.

Now, to program the module you need to desolder the GPIO0 jumper and move it to the "0" position.

Back to tools and select your COM port.

Click the upload icon (right facing arrow).

When upload is done, unplug and replug the WiFi module from the FTDI cable but do not unplug the USB end from the computer.

Back to tools and click "esp8266 sketch data upload".

when done remove the module and resolder the GPIO0 jumper back to position "1".

Congratulations, it's now programmed.

====== Precompiled binaries (similar to step 3 shortcut in the tutorial above) ======
attached the compiled binaries for use with the WEMOS D1 Mini, including the SPIFFS filesystem .bin

the SSID is "GS450H-VCU" and the WiFi password is ''`inverter123`''

https://openinverter.org/forum/download/file.php?id=9051

https://openinverter.org/forum/download/file.php?id=9050

=== Common Issues ===

* [[File:ESP8266 communication with DuPont jump leads and without.png|thumb|If experiencing connection issues, try different cables to rule out bad connectors ( apparently common with recent Olimex)]]The settings & partition size in Arduino Studio are easy to get wrong. [https://openinverter.org/forum/viewtopic.php?p=29523#p29523]
* If you get any of: 1) incomplete responses via HTTP 2) patchy WiFi on a logic board 3) parameters from logic board not loading in web interface; you can try powering the ESP8266 from a different source, or connect it via DuPont leads to rule out connector & plug issues (see photographs).
* If you are all out of luck, there are alternative boards discussed here [https://openinverter.org/forum/viewtopic.php?t=2299]
[[Category:OpenInverter]] [[Category:ESP8266]]

MEB Batteries

2025-02-19T12:19:36Z

Jason arnold: added info on module connections

[[File:MEB Battery.jpg|thumb|MEB Battery]]
[[File:MEB Battery modules.jpg|thumb|MEB Battery modules]]
[[File:MEB communication connector.jpg|thumb|MEB communication connector]]

== Overview ==
Volkswagen have specified a standard module that always has the same dimensions (590x225x110mm) and comes in 3P8S (82 kWh batteries) and 2P12S (48, 55, and 62 kWh) flavours. Each module has an energy content of 6.85 kWh.

Forum thread: https://openinverter.org/forum/viewtopic.php?t=1948

It comes along with 4 relays where 2 make the connection to the drive train and the other 2 make the connection to the quick charge port. It uses a varying number of module units that measure voltage and module temperature and execute balancing commands with about 100 mA of balancing current. The CAN protocol of these modules has been reverse engineered by Tom de Bree and a compact [https://github.com/jsphuebner/stm32-car/blob/touran-meb/src/mebbms.cpp high level implementation] was done by Johannes.

There is also a HV controller that performs the high level BMS calculations, controls the contactors and various other tasks but its protocol has not been reverse engineered.

== Module Connections ==

* Battery terminals: M6
* BMS connectors: restricted TE part, however, the harness is available from VW (0Z1 971 690 for 12S modules, 8S may be different)

[[Category:VAG]] [[Category:Battery]]

VW Electromechanical Power Steering Rack

2025-01-17T08:22:21Z

Jason arnold: Added "Column" section with part numbers

VW and other VAG group Vehicles prior to switching to an electric steering column for assist had an electrically assisted steering rack. Golf MK5 for example.
{| class="wikitable"
|+
!Part Number
!Generation
!Vehicle
!Market
|-
|1K1 909 144 L
|MK5
|VW Golf
|LHD
|-
|1K2 909 144 F
|MK5
|VW Golf
|RHD
|}
{{DISPLAYTITLE:VW Electromechanical Power Steering Rack}}
[[File:VW electric steering rack.jpg|none|thumb]]

=== Wiring ===
The rack can be used in failsafe mode simply by providing power to the unit as follows:

* There's a 2 pin connector with beefy pins: connect pin 2 to a permanent 12V though an 80 amp fuse, connect pin 1 to ground. Enable the rack though a switched/ignition 12V feed (10A fuse) to pin 4 (EN) of the smaller data connector.

If you want to use dynamic assist levels, you'll need to connect pin 1 to CAN-L and pin 2 to CAN-H, and send out the RPM on 0x280 where Bytes 2 and 3 are RPM*4. This must be above 600 for it to provide assistance.

The rack broadcasts 0x3D0 and 0x3D2
[[File:Rack Pins.jpg|thumb|Rack Pins|none]]

===Column===
1K1 419 502 xx (LHD) and 1K2 419 502 xx (RHD) are compatible VAG columns. The part number seems to cover a variety of models from 1999 through 2018, and perhaps even later. The "xx" denotes a few variations in mounting, but the coupling to the rack as well as the steering wheel mount, should all be the same.

[[Category:VAG]]
[[Category:Power Steering]]

{{DEFAULTSORT:VW_Electromechanical_powersteering_rack}}

Volvo Power Steering Pump

2024-12-12T07:55:55Z

Jason arnold: Added spec'd fluid

== Part Numbers and Versions ==
[[Category:OEM]]
[[Category:Volvo]]
[[Category:Power Steering]]
{| class="wikitable"
|+Part Numbers<ref>https://rusefi.com/forum/viewtopic.php?p=45946#p45946</ref>
!Part Number
!Vehicle Used in
!Comment
|-
|30636927
|2004-2013 C30 C70 V50 S40
|unverified
|-
|31202520
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36000075
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36000116
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36000772
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36000801
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36001211
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36001485
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36002698
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36050678
|2004-2013 C30 C70 V50 S40
|unverified
|-
|8603041
|2004-2013 C30 C70 V50 S40
|unverified
|-
|8603274
|2004-2013 C30 C70 V50 S40
|unverified
|}

== Electrical Connection ==
Input signals, start and stop conditions described in S40 service manual<ref>https://www.volvo-forums.com/attachments/s40my2005_suspensionsteering-pdf.7233/</ref>

The harness for the motor supply can be bought completely (Part Number: 30775461 <ref>https://usparts.volvocars.com/p/Volvo_2007_C30-24l-5-cylinder/Wiring-Harness-Cable-Harness-Power-Steering-Pump-Electrohydraulic-Power-Steering-Service-Solution-Servo-Pump/42906949/30775461.html (Backup: )</ref>) or just the connector. There is connector kits available online (avoid the pig-tail version as the cable is way undersized. [https://www.ebay.de/itm/264183247309?_nkw=Electric+Power+Steering+%28EPS%29+Pump+Wire+Connector+Kit+Type+1+Fit+for+Volvo+Ford&itmmeta=01J64V8R3PQKQS2EKGFX7V5BVM&hash=item3d828c71cd:g:9YsAAOSwkvtb3Qd3&itmprp=enc%3AAQAJAAABMHoV3kP08IDx%2BKZ9MfhVJKnq1cduF5WgneJWcf2KOIwYLjdi97A8lf5OlJCgf3lStwgB7DXBbzWP5qft6Wq1wk68P2yrbn6NspdbHXbMs%2Fo1lKpey0MBk2Dqf%2BYimnPZ2JcaYs6l1vtYvLq%2FTbkcfppJYbhQ6U1IcaY0%2BTcZ1LLNcMEsG1cAazAwdRpglFiU3VmsIb3MOC9ZgJtYJ0XEm8XvmXBFsGZb9PJlyyXlp5YtkKGxAAM0H0gjTcEUfTXFlbl8jiyw3ziYa%2FjJuc2Db%2B15Kf%2BAQY%2FhWSFyBkaSZK1%2FUit%2FC2tF3wKqv2UPWRrfcw1BV%2BWd1HzbLSbvObyYLAklc%2FNhtRoWci2FP0azltlwmEtiiOaGp4YI1cFSiJtqqDMZeeZSWI8j0AvO6hbAROI%3D%7Ctkp%3ABk9SR4CCo5uxZA Link])
{| class="wikitable"
|+Connector A<ref name=":0">Volvo C30 2007 Schematic, TP39103202</ref>, Part Number: 31266849<ref>https://usparts.volvocars.com/p/Volvo_2007_C30-24l-5-cylinder/Receptacle-Housing-Cable-Harness-Engine-Component-Parts-Electrical-Power-Steering-Module-EPS/42815694/31266849.html</ref>(not verified)
!Pin Number
!Cable Color
!Function
!Comment
|-
|1
|Red
| Permanent +12V for Motor
|Fused with 80A fuse (F2)
|-
|2
|Black
|GND
|
|}
{| class="wikitable"
|+Connector B<ref name=":0" />, Part Number: '''31346135'''<ref>https://usparts.volvocars.com/p/Volvo_2007_C30-24l-5-cylinder/Receptacle-Housing-Electric-Power-Steering-EPAS-Electrical-Power-Steering-Module-PSCM/65250641/31346135.html</ref>(not verified)
!Pin Number
!Cable Color
!Function
!Comment
|-
|1
|Grey-Blue
|Ignition +12V for Control
|Fused with 10A fuse (F53)
|-
|2
|
|CAN-??
|
|-
|3
|
|CAN-??
|
|}

A visual guide of the pinout can be found on [https://www.maxxecu.com/webhelp/can_peripheral_control_volvo_powersteering.html this MaxxECU online help page]

== CAN Bus Control ==
The CAN bus protocol has been reverse engineered in the RusEFI forum<ref>https://www.rusefi.com/forum/viewtopic.php?f=4&t=2329</ref> and a LUA script example exists<ref>https://github.com/rusefi/rusefi/blob/master/firmware/controllers/lua/examples/Volvo-electric-power-steering-pump.txt</ref>

Alternatively, there is an implementation using Arduino code<ref>https://github.com/NMSTEC/Volvo_EPS_FREE</ref>
== Mechanical Properties ==

=== Dimensions ===
Approx. 12" x 7" x 7" (305mm x 178mm x 178mm)

=== Fittings ===

* High pressure side (pump supply/outlet): M16x1.5 (you can use adapters like this one: https://www.ebay.de/itm/192079081475)
* Low pressure side (pump return/inlet) is just a hose. The fitting on the reservoir is likely 10mm (3/8").

=== Mounting Bracket ===
WillFab Motorsport (WFM) produces a universal fit bracket for this pump. Available [https://towytrailercentre.co.uk/products/volvo-electric-power-steering-pump-bracket-s40-v50-c30-c70-mount-drift-rally-wfm here] and [https://www.ebay.co.uk/str/wfmttc here].

== Fluid ==
Pentosin CHF 202 is spec'd in the Volvo manual.

== References ==
<references />

Volvo Power Steering Pump

2024-12-12T07:45:38Z

Jason arnold: /* Mechanical Properties */ added dimensions

Volvo Power Steering Pump

2024-12-12T07:32:19Z

Jason arnold: /* Part Numbers and Versions */ added source vehicles and made general formatting improvements; clarified fittings info

== Part Numbers and Versions ==
[[Category:OEM]]
[[Category:Volvo]]
[[Category:Power Steering]]
{| class="wikitable"
|+Part Numbers<ref>https://rusefi.com/forum/viewtopic.php?p=45946#p45946</ref>
!Part Number
!Vehicle Used in
!Comment
|-
|30636927
|2004-2013 C30 C70 V50 S40
|unverified
|-
|31202520
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36000075
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36000116
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36000772
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36000801
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36001211
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36001485
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36002698
|2004-2013 C30 C70 V50 S40
|unverified
|-
|36050678
|2004-2013 C30 C70 V50 S40
|unverified
|-
|8603041
|2004-2013 C30 C70 V50 S40
|unverified
|-
|8603274
|2004-2013 C30 C70 V50 S40
|unverified
|}

== Electrical Connection ==
Input signals, start and stop conditions described in S40 service manual<ref>https://www.volvo-forums.com/attachments/s40my2005_suspensionsteering-pdf.7233/</ref>

The harness for the motor supply can be bought completely (Part Number: 30775461 <ref>https://usparts.volvocars.com/p/Volvo_2007_C30-24l-5-cylinder/Wiring-Harness-Cable-Harness-Power-Steering-Pump-Electrohydraulic-Power-Steering-Service-Solution-Servo-Pump/42906949/30775461.html (Backup: )</ref>) or just the connector. There is connector kits available online (avoid the pig-tail version as the cable is way undersized. [https://www.ebay.de/itm/264183247309?_nkw=Electric+Power+Steering+%28EPS%29+Pump+Wire+Connector+Kit+Type+1+Fit+for+Volvo+Ford&itmmeta=01J64V8R3PQKQS2EKGFX7V5BVM&hash=item3d828c71cd:g:9YsAAOSwkvtb3Qd3&itmprp=enc%3AAQAJAAABMHoV3kP08IDx%2BKZ9MfhVJKnq1cduF5WgneJWcf2KOIwYLjdi97A8lf5OlJCgf3lStwgB7DXBbzWP5qft6Wq1wk68P2yrbn6NspdbHXbMs%2Fo1lKpey0MBk2Dqf%2BYimnPZ2JcaYs6l1vtYvLq%2FTbkcfppJYbhQ6U1IcaY0%2BTcZ1LLNcMEsG1cAazAwdRpglFiU3VmsIb3MOC9ZgJtYJ0XEm8XvmXBFsGZb9PJlyyXlp5YtkKGxAAM0H0gjTcEUfTXFlbl8jiyw3ziYa%2FjJuc2Db%2B15Kf%2BAQY%2FhWSFyBkaSZK1%2FUit%2FC2tF3wKqv2UPWRrfcw1BV%2BWd1HzbLSbvObyYLAklc%2FNhtRoWci2FP0azltlwmEtiiOaGp4YI1cFSiJtqqDMZeeZSWI8j0AvO6hbAROI%3D%7Ctkp%3ABk9SR4CCo5uxZA Link])
{| class="wikitable"
|+Connector A<ref name=":0">Volvo C30 2007 Schematic, TP39103202</ref>, Part Number: 31266849<ref>https://usparts.volvocars.com/p/Volvo_2007_C30-24l-5-cylinder/Receptacle-Housing-Cable-Harness-Engine-Component-Parts-Electrical-Power-Steering-Module-EPS/42815694/31266849.html</ref>(not verified)
!Pin Number
!Cable Color
!Function
!Comment
|-
|1
|Red
| Permanent +12V for Motor
|Fused with 80A fuse (F2)
|-
|2
|Black
|GND
|
|}
{| class="wikitable"
|+Connector B<ref name=":0" />, Part Number: '''31346135'''<ref>https://usparts.volvocars.com/p/Volvo_2007_C30-24l-5-cylinder/Receptacle-Housing-Electric-Power-Steering-EPAS-Electrical-Power-Steering-Module-PSCM/65250641/31346135.html</ref>(not verified)
!Pin Number
!Cable Color
!Function
!Comment
|-
|1
|Grey-Blue
|Ignition +12V for Control
|Fused with 10A fuse (F53)
|-
|2
|
|CAN-??
|
|-
|3
|
|CAN-??
|
|}

A visual guide of the pinout can be found on [https://www.maxxecu.com/webhelp/can_peripheral_control_volvo_powersteering.html this MaxxECU online help page]

== CAN Bus Control ==
The CAN bus protocol has been reverse engineered in the rus EFI forum<ref>https://www.rusefi.com/forum/viewtopic.php?f=4&t=2329</ref> and a LUA script example exists<ref>https://github.com/rusefi/rusefi/blob/master/firmware/controllers/lua/examples/Volvo-electric-power-steering-pump.txt</ref>

Additionally an implementation using arduino code<ref>https://github.com/NMSTEC/Volvo_EPS_FREE</ref>

== Mechanical Properties ==

=== Fittings ===

* High pressure side (pump supply/outlet): M16x1.5 (you can use adapters like this one: https://www.ebay.de/itm/192079081475)
* Low pressure side (pump return/inlet) is just a hose. The fitting on the reservoir is likely 10mm (3/8").

=== Mounting Bracket ===
WillFab Motorsport (WFM) produces a universal fit bracket for this pump. Available [https://towytrailercentre.co.uk/products/volvo-electric-power-steering-pump-bracket-s40-v50-c30-c70-mount-drift-rally-wfm here] and [https://www.ebay.co.uk/str/wfmttc here].

== References ==
<references />

BMW Electronic Throttle Pedal

2024-11-28T11:00:18Z

Jason arnold: /* Connector */

==General Information==
The pedal module has two independently working sensors (potentiometer or hall effect) for redundancy and plausibility checks. Sensor 2 outputs exactly half the voltage of Sensor 1.

In the original design the DME (Digital Motor Electronics) provides an independent, precision +5V sources for each of the two sensors. It should be noted here that the +5V supply voltage should be precise and stable to assure no erroneous readings from the Inverter Controller.

=== Pinout and Nominal Voltages ===
The Accelerator Pedal Module for manual and automatic gearbox do not differ in their pinout or electrical connector used. The nominal voltage values are the same for all pedal versions.

{| class="wikitable"
|+Nominal Voltage Range
!Position
!Voltage Sensor 1
!Voltage Sensor 2
|-
|Idle
|0.70-0.80V
|0.31-0.43V
|-
|Full Load
|3.65-4.10V
|1.83-2.04V
|-
|Resistance Point Kickdown
|4.27-4.33V
|2.14-2.16V
|-
|Mechanical Stop
|<4.76V
|<2.38V
|}

=== Connector ===

The matching cable connector is made by TE Connectivity.

{| class="wikitable"
|-
! Component !! Part No !! Link
|-
|Housing
|1-967616-1
|https://www.te.com/en/product-1-967616-1.html
|-
|Terminal
|5-962885-1
|https://www.te.com/en/product-5-962885-1.html
|-
|Cable Seal
|1-967067-1
|https://www.te.com/en/product-1-967067-1.html
|}

These parts are readily available from RS Components, Farnell, Digikey and Mouser. Ebay and Aliexpress have affordable clones with or without wire pigtails attached.

==Accelerator Pedal Version 1==
[[File:BMW E46 Throttle Pedal.png|thumb|BMW E46 Throttle Pedal Schematic]]
[[File:BMW E46 Throttle Pedal ETK.png|thumb|BMW E46 Throttle Pedal ETK [https://www.bmw-etk.info/parts-catalog/prd/BMW/VT/P/E46/Cou/318Ci%20N42/ECE/L/N/2003/01/47611/35/35_0282]]]
{| class="wikitable"
|+Pinout and Cable Colors
(from E46, may vary for other vehicles)
!Pin Number
!Cable Color
!Function
|-
|1
|Brown-Green
|Ground
|-
|2
|Brown
| Ground
|-
|3
|Yellow-Green
| +5V Supply
|-
|4
|White
|Signal Sensor 1
|-
|5
|Yellow
| +5V Supply
|-
|6
|White-Green
|Signal Sensor 2
|}
{| class="wikitable"
|+Part Numbers (derived from E46, might vary for other vehicles)
!No
!Description
!Part Number
!Vehicles Used
!Status
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 40 1165703
|
|Until 10/1999
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 40 6753053
|
|Until 08/2000
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 40 6753518
|
|Until 11/2001
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 40 6756492
|
|Until 05/2002
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 40 6762480
|
|Until 02/2006
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 42 6772705
|
|Until 05/2008
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 42 6786281
|E38, E39, E46, E53
|
|-
|
|
|
|
|
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 40 1165704
|
|Until 10/1999
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 40 6753094
|
|Until 07/2001
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 40 6753519
|
|Until 03/2002
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 40 6756493
|
|Until 06/2002
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 40 6762481
|
|Until 02/2006
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 42 6772706
|
|Until 07/2008
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 42 6786282
|E38, E39, E46, E52, E53
|
|-
|
|
|
|
|
|-
|02
|Adapter Plate, Accelerator Pedal Module
|35 42 6772703
|
|
|-
|02
|Adapter Plate, Accelerator Pedal Module
|35 42 6772704
|
|
|-
|03
|Torx-bolt with washer, M8x20
|07 12 9905423
|
|
|-
| 04
|Accelerator Pedal Bracket
|35 41 1163875
|
|Until 09/2003
|-
|04
|Frame
|32 30 3411677
|
|From 2003/09
|-
|05
|Self-locking hex nut, M6
|07 14 7153450
|
|From 07/2007
|-
|06
|Blind plug, D=25mm
| 35 41 1163890
|
|
|-
|07
|Socket Housing 6 Pin
|61 13 8383300
|
|
|-
| --
|Bushing contact 0.2-0.5mm²
|61 13 0005197
|
|
|}

==Accelerator Pedal Version 2==
[[File:BMW E60 Throttle Pedal.png|thumb|BMW E60/E61 Throttle Pedal Schematic]]

[[File:BMW E60 Throttle Pedal ETK.png|thumb|BMW E60/E61 Throttle Pedal ETK [https://www.bmw-etk.info/parts-catalog/prd/BMW/VT/P/E60/Lim/520d/ECE/L/N/2005/02/48801/35/35_0274]]]
{| class="wikitable"
|+Pinout and Cable Colors
(from E60/E61, may vary for other vehicles)
!Pin Number
!Cable Color
!Function
|-
|1
|Brown-Green
|Ground
|-
|2
|Brown-Blue
|Ground
|-
|3
| Yellow-Blue
| +5V Supply
|-
|4
|White-Green
|Signal Sensor 1
|-
|5
|Yellow-Green
| +5V Supply
|-
| 6
|White-Blue
| Signal Sensor 2
|}
{| class="wikitable"
|+Part Numbers (derived from E60/E61, may vary for other vehicles)
! No
!Description
!Part Number
!Vehicles Used
!Status
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 41 6754783
|
|Until 11/2001
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 41 6759724
|
|Until 12/2005
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 40 6766931
|
|Until 02/2006
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 41 6762327
|
|Until 04/2008
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 42 6772646
|
|Until 07/2008
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 42 6788633
|
|Until 12/2009
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 42 6786286
|
|Until 08/2011
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 42 6789999
|
|Until 10/2012
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 42 6852643
|
|Until 06/2013
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 42 6858575
|E60, E61, E63, E64, E83, E85, E89, E90, E91, E92, E93,
F10, F11, F18, F25
|Until 08/2014
|-
|01
| Accelerator Pedal Module, Manual Gearbox
|35 42 6860785
|E60, E61, E63, E64, E83, E84, E85, E89, E90, E91, E92, E93,
F10, F11, F18, F25
|Until 09/2015
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 42 6860000
|E60, E61, E63, E64, E83, E84, E85, E89, E90, E91, E92, E93,
F10, F11, F18, F25, F45, F46, F48
|Until 07/2020
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 40 6889823
|E60, E61, E63, E64, E83, E84, E85, E89, E90, E91, E92, E93,
F10, F11, F25, F26, F39, F45, F46, F48,

G29
|
|-
|
|
|
|
|
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 41 6752614
|
|Until 11/2001
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 41 6759723
|
|Until 09/2004
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 42 6766930
|
|Until 01/2006
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 42 6772645
|
|Until 08/2008
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 42 6786285
|
|Until 07/2011
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 40 6762326
|
|Until 08/2011
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 42 6852644
|
| Until 03/2012
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 42 6858574
|E60, E61, E63, E64, E65, E66, E67, E68, E70, E71, E72, E83, E85, E86, E89, E90, E91, E92, E93,
F01, F02, F03, F04, F06, F07, F10, F11, F12, F13, F18, F25
|Until 06/2013
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
| 35 42 6859999
|E60, E61, E63, E64, E70, E71, E83, E84, E85, E89, E90, E91, E92, E93,

F06, F25, F45, F46, F48,

G11, G12
| Until 07/2020
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 40 6889822
|E60, E61, E63, E64, E65, E70, E71, E72, E83, E84, E85, E89, E90, E91, E92, E93,
F01, F02, F04, F05, F06, F07, F10, F11, F12, F13, F25, F26, F39, F45, F46, F48,

G11, G12, G14, G15, G16, G28, G29, G30, G31, G32
|
|-
|
|
|
|
|
|-
|02
|Filister Head Screw M6x16
|07 12 9905536
|
|
|-
|02
|ISA Screw M6x16
| 07 12 9904588
|
|
|-
|03
|Cover D=10mm
| 35 42 6796540
|
|
|-
|04
|Cable Clamp A=3.5-6.0mm
|07 14 7547239
|
|
|-
|05
|Socket Housing 6 Pin
|61 13 8383300
|
|
|-
| --
|Pins for Socket Housing MQS ELA 0.75mm²
|61 13 8366260
|
|
|}

==Accelerator Pedal Version 3==
[[File:BMW E87 Throttle Pedal.png|thumb|BMW E81/E82/E87/E88 Throttle Pedal Schematic]]

{| class="wikitable"
|+Part Numbers (derived from E87, might vary for other vehicles)
!No
!Description
!Part Number
!Vehicles Used
!Status
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 42 6770935
|
|Until 02/2008
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 42 6786589
|
|Until 07/2009
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 42 6789529
|
|Until 06/2013
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 42 6793742
|
|Until 06/2013
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 42 6853176
|
|Until 03/2020
|-
|01
|Accelerator Pedal Module, Manual Gearbox
|35 40 6889819
|
|
|-
|
|
|
|
|
|-
|01
|Accelerator Pedal Module, Manual Gearbox (Stainless Steel Pad)
|35 42 6791474
|
|
|-
|
|
|
|
|
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 42 6786588
|
|Until 11/2009
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 42 6770936
|
|Until 10/2011
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 42 6789528
|
|Until 06/2013
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 42 6793743
|
|Until 06/2013
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 42 6853175
|
|Until 03/2020
|-
|01
|Accelerator Pedal Module, Automatic Gearbox
|35 40 6889818
|
|
|-
|
|
|
|
|
|-
|02
|Fillister head screw, M6x16
|07 12 9905536
|
|
|-
|02
|ISA screw, M6x16
|07 12 9904588
|
|
|-
|03
|Cover bolt D=10mm
|35 42 6796540
|
|
|-
|04
|Cable Clamp A=3.5-6.0mm
|07 14 7547239
|
|
|-
|05
|Socket Housing 6 Pin
|61 13 8383300
|
|
|-
| --
|Pins for Socket Housing MQS ELA 0.75mm²
|61 13 8366260
|
|
|}
ETK Link: https://www.bmw-etk.info/parts-catalog/prd/BMW/VT/P/E87/SH/116i/ECE/L/N/2003/04/48922/35/35_0274/07129904588
[[Category:OEM]]
[[Category:BMW]]
[[Category:Accessories]]
[[Category:Accelerator pedals and position sensors]]

Cooling System Design

2024-10-22T11:56:43Z

Jason arnold:

== Overview ==
As power levels of EV conversions increase, thermal management is becoming more important as a design consideration. Too often, this is treated as an afterthought, even by so-called "professional" shops. This guide is here to serve as a primer on the subject, and, while not exhaustive, it will address the major concepts needed and common mistakes seen in DIY builds.

For the moment, this guide will stick to the scope of ambient cooling (i.e. using a pump to circulate coolant through components, and then to a radiator to reject the heat). Sub-ambient cooling (i.e. using refrigerant to cool to temperatures below ambient) may eventually be added as the practice becomes more common in conversions.

== Cooling System Concepts ==
Terminology (WIP):

* Head
* Pressure
* Flow
* Delta
* Prime/cavitation

== Cooling System Components ==

=== Typical Component Layout ===
An established layout for a simple cooling loop is as follows:

# The "start" of the loop is the header tank, which is mounted at the highest point in the system. By being the high point, the tank supplies "head" to the downstream components, and also serves as uppermost point for any air in the system to return to. The header tank will typically have two fittings: the one on the bottom will be the supply/output, the one on the side will be the return/inlet. There will also sometimes be a fitting next to the cap to allow for expansion/overflow conditions.
# The pump should come directly after the header tank. Having the pump here assures that the pump will see coolant that is both cool and free of air, two important factors for the longevity of the pump. Also, having the pump primed directly by the header tank will allow it to "push" coolant (rather than pull it), which is how centrifugal pumps are meant to operate.
# The load(s) comes next. In a simple loop, this might just be a single component (e.g. inverter), but it's not uncommon to have multiple components in a loop. The rule of thumb is that the most heat-sensitive components come first; so if you have an inverter and a motor in a coolant loop, the inverter always comes first because its operational range is <90°C, whereas a motor can see temperatures well over 100°C.
# The heated coolant then goes into a radiator (sometimes called heat exchanger). In a radiator with top and bottom fittings, the top is the inlet and the bottom is the outlet. This is because warm coolant is less-dense and as it cools by passing though the radiator, it will get heavier and flow downwards naturally.
# Lastly, after leaving the radiator, the cooled coolant returns to the header tank through the return/inlet on the side of the tank. Because the inlet is higher than the outlet, any air trapped in the system will separate out of the coolant when it flows through here.

== Troubleshooting ==
Some important things to ask: <ref>https://openinverter.org/forum/viewtopic.php?t=5370</ref>

* Is your radiator getting enough airflow?
* Are your fans running?
* Where can air get trapped in your setup?

Because DIY coolant loops tend to be less than ideally-routed, an "airlift" type vacuum-based tool for filling your system is strongly recommended.

== References ==

Cooling System Design

2024-10-22T11:56:06Z

Jason arnold: added Troubleshooting section

2024-06-11T03:43:25Z

Jason arnold: Added more info to Connector Part Numbers

== Connector Part Numbers <ref>https://www.bosch-ibusiness.com/products/product-categories/auxiliary-pumps-and-valves/pce-0392024078/</ref><ref>https://www.bosch-ibusiness.com/media/images/xx_pdfs_4/katalog_2023.pdf#page=62</ref> ==
'''Pigtail'''

* VW: 4F0 973 703

'''Housing'''

* TE Connectivity "MCON 1.2" series: 1488991-6 (with CPA),…-2 w/o CPA
* Molex "MXP120" series: 34900-3102

'''Terminals'''

* Bosch: 1 928 498 811
* Tyco/Molex MCON 1.2" series: 1670146-3 – Ag plated (20awg)
* KOSTAL MLK 1.2: 32124734130

'''Seal'''

* Bosch: 1 928 300 936
* TE Connectivity: 967067-1 (20 awg)
* KOSTAL: 10800507250

[[File:Pce connector.webp|none|thumb]]

== Operation ==
Pump can be run without the signal (S) pin connected. This will operate the pump at maximum speed. There is a 2 second startup delay if the pump is to be operated without the signal (S) pin connected.
[[File:Mounting orientations.png|none|thumb]]
If the pump detects that it is being run dry, it will turn itself off, try again, but will quit if unsuccessful >20 times

Signal pin can be provided a 12v PWM to control the speed<ref>https://www.cascadiamotion.com/images/documents/Bosch_PCE-XL_Quick_Start_Guide.pdf</ref>

= References =
<references />

[[Category:OEM]] [[Category:VAG]] [[Category:Accessories]]

2023-06-17T09:19:52Z

Jason arnold: /* Overview: */

Category:Tesla

2023-06-16T00:56:22Z

Jason arnold: /* Model S/X */ added Ancillaries sub-heading as well as Coolant Pump linky

==Model S/X==
===Drive Units===
*[[Tesla Model S/X Small Drive Unit ("SDU")|Small Drive Unit ("SDU")]]
*[[Tesla Model S/X Large Drive Unit ("LDU")|Large Drive Unit ("LDU")]]
===Other HV systems===
*[[Tesla Model S/X GEN2 Charger|L2 AC Charger (GEN2)]]
*[[Tesla Model S GEN1 Charger|L2 AC Charger (GEN1)]]
*[[Tesla Model S GEN1 Rear HVJB|Rear HVJB (GEN1)]]
*[[Tesla Model S Front HVJB|Front HVJB (GEN2 - Model S only)]]
*[[Tesla Model S/X DC/DC Converter|DC-DC converter (GEN2)]]
*[[Tesla Model S/X A/C Compressor|A/C compressor (GEN1)]]
*[[Tesla Model S/X A/C Compressor Gen2|A/C Compressor (GEN2)]]
*[[Tesla Model S Battery Heater|Battery heater (Model S only)]]

=== Ancillaries ===

* [[Tesla Model S/X Coolant Pump|Coolant Pump]]

==Model 3/Y==
===Drive Units===
*[[Tesla Model 3 Front Drive Unit|Front Drive Unit]]
*[[Tesla Model 3 Rear Drive Unit|Rear Drive Unit]]
===Other HV systems===
*[[Tesla Model 3 Battery|Battery]]
*[[Tesla Model 3 Contactors|Contactors]]
* [[Tesla Model 3 Charger/DCDC ("PCS")|L2 Charger & DC-DC ("PCS")]]
==Resources==
*[[Tesla CAD Models]]
*[https://epc.tesla.com/en/catalogs Tesla EPC (Electronic Parts Catalogue)]
==Sourcing Tesla Drive Units==
{| class="wikitable"
|+2012-2017* Model S/X Drive Units
!Trim Designation
!Front Drive Unit
!Rear Drive Unit
|-
|'''##'''
|''N/A''
|Base LDU
|-
|'''P##'''
|''N/A''
|Sport** LDU
|-
| '''##D'''
|SDU
|SDU
|-
|'''P##D'''
|SDU
|Sport LDU
|-
| colspan="3" | * Depending on the source, in either 2017 or 2019 Tesla began changing drive unit selections in the Model S and X
<nowiki>**</nowiki>UPDATED 6 May 2021: Based on thread found here: [https://openinverter.org/forum/viewtopic.php?f=10&t=1625 Teardown - Tesla LDU - Inverter - openinverter forum], the base and sport LDUs use different IGBTs
|}SDU: Small Drive Unit (note: there are two different cases for the SDU, front and rear)

LDU: Large Drive Unit

Tesla Model S/X Coolant Pump

2023-06-16T00:51:51Z

Jason arnold: added References header

== Overview: ==
[[File:Tesla Model S-X Coolant Pump.jpg|alt=Tesla Model S-X Coolant Pump|thumb|Tesla Model S/X Coolant Pump]]
Both the Model S and X use a very capable (but curiously unbranded) coolant pump. Internet research seems to indicate it may be made by VariMax<ref name=":0">https://www.diyelectriccar.com/threads/the-teslorean.170770/post-856074</ref>, though there are so many Tesla part numbers it's hard to say which actual model it is.

In ICE circles, this pump is commonly used in high performance intercooler systems, so Lingenfelter Performance Engineering has compiled a fairly thorough (though questionably formatted) [https://www.lingenfelter.com/PDFdownloads/L330070000.pdf datasheet on the pump]. Another fairly thorough overview can be found within the [https://www.evcreate.com/using-tesla-thermal-management-system-parts/#tesla-pump EV Create overview of the Tesla cooling system]<ref>https://www.evcreate.com/using-tesla-thermal-management-system-parts/#tesla-pump</ref>.

== Specs ==
Some basic specs for the pump are as follows<ref name=":0" />:

- Target flow rate 720 LPH @ 70 kPa

- Inlet / Outlet connection: 19 MM Barb

- Motor syle: Brushless

- Operating voltage: 8-16 VDC

- Maximum amp draw: 7.3 Amp

== Control ==
The pump can be controlled using PWM. The PWM voltage is 5V and the frequency is a rather unusual 2Hz. The pump speed can be controlled from ~750RPM at 20% duty cycle to ~5000RPM at 80% duty cycle.

== Wiring ==

=== Connector ===
The pump has a single 4-pin plug which contains both the power and control signals. The plug itself is Sumitomo “RS” series:

- socket (female): 6189-7757

- retainer: 6918-1599

- pins (female): 8240-0263 (0.3-0.5mm2/24-20ga), 8240-0264 (0.85-1.25mm2/20-18ga), 8240-0265 (2.0mm2/16-14ga)

- seals (cable OD): 7165-0474 (1.0-1.4mm), 7165-0473 (1.5-1.9), 7165-0472 (2.0-2.4), 7165-0471 (2.5-2.9/18ga)

As Sumitomo connectors aren't widely available, a better source for this connector is Aliexpress where is is often sold as a complete connector kit

=== Pinout ===
[[File:Tesla Model S-X Coolant Pump pinout.jpg|alt=Tesla Model S-X Coolant Pump pinout (photo courtesy of EVcreate)|none|thumb|Tesla Model S-X Coolant Pump pinout (photo courtesy of EVcreate)]]

== Issues ==
The pump has a flow sensor, so it will not run empty/dry. Even when primed, the pump takes a moment to spool up.

Annoyingly, the bearing is integral to the impeller, so if you have a noisy pump there is no way to replace just the worn part.

== References ==