BMW i3 Inverter - Revision history

Tom91: Categories

2024-12-20T16:34:44Z

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

2024-05-11T16:55:20Z

Updated series resistor value for pin 35 on Harwin connector

← Older revision		Revision as of 16:55, 11 May 2024
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	'''Mod 5.''' '''Gate driver PSU power pin'''		'''Mod 5.''' '''Gate driver PSU power pin'''

	Pin 35 of the Harwin connector to the gate driver board is not connected to anything. Testing indicates this must be powered for the gate driver to work, at least on some boards. The motor has been run successfully with [https://openinverter.org/forum/viewtopic.php?p=70213#p70213 5V to this pin via a ~~10K~~ resistor from the adjacent pin 34], which receives power from the openinverter's 5V supply. Some earlier notes in the i3 hacking thread suggest it may also have been tested with 12V.		Pin 35 of the Harwin connector to the gate driver board is not connected to anything. Testing indicates this must be powered for the gate driver to work, at least on some boards. The motor has been run successfully with [https://openinverter.org/forum/viewtopic.php?p=70213#p70213 5V to this pin via a 100 Ohm resistor from the adjacent pin 34], which receives power from the openinverter's 5V supply. Some earlier notes in the i3 hacking thread suggest it may also have been tested with 12V.

CJW: Clarified wording

2024-04-27T18:49:07Z

Clarified wording

← Older revision		Revision as of 18:49, 27 April 2024
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	</syntaxhighlight>		</syntaxhighlight>

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


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

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

CJW at 18:44, 27 April 2024

2024-04-27T18:44:51Z

CJW at 18:38, 27 April 2024

2024-04-27T18:38:33Z

← Older revision		Revision as of 18:38, 27 April 2024
Line 289:		Line 289:

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

	'''<big>Motor Resolver & Temperature Sensors</big>'''		'''<big>Motor Resolver & Temperature Sensors</big>'''
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	The 40 pin surface mount Harwin connector to the gate driver board may have dry joints or shorts.		The 40 pin surface mount Harwin connector to the gate driver board may have dry joints or shorts.
			'''Mod 5.''' '''Gate driver PSU on pin'''

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

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

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

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

2024-04-27T18:37:19Z

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

← Older revision		Revision as of 18:37, 27 April 2024
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	'''Overview'''		'''<big>Overview</big>'''

	There are 2 variants of the i3, the standard i3 with motor power rated at 125kW and the i3s rated at 135kW.		There are 2 variants of the i3, the standard i3 with motor power rated at 125kW and the i3s rated at 135kW.
Line 19:		Line 19:


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

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

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

	Pinouts for the three connectors on this board below.

	{\| class="wikitable"		{\| class="wikitable"
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	\|35		\|35
	\|I		\|I
	\|IGBT PSU 12V on		\|IGBT PSU on (5V or 12V)
	\|		\|
	\|-		\|-
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	\|}		\|}

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

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

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

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

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

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

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


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


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

	The BMW i3 gate driver board communicates the DC bus voltage (ie traction battery voltage) and IGBT heatsink temperatures to the Openinverter via SPI.		The BMW i3 gate driver board communicates the DC bus voltage (ie traction battery voltage) and IGBT heatsink temperatures to the Openinverter via SPI.
Line 390:		Line 390:
	DigIo::err_out.Configure(GPIOC, GPIO10, PinMode::INPUT_FLT);		DigIo::err_out.Configure(GPIOC, GPIO10, PinMode::INPUT_FLT);
	</syntaxhighlight>		</syntaxhighlight>

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

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

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

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

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

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


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

	~~As of 12 April 2024, page 10 of the~~ forum ~~i3 controller hacking thread (link posted at the top of this page) contains an~~ initial set of parameters ~~that were successfully~~ used for bench testing a motor with a pair of lead acid car batteries. Will update and eventually post a full set of parameters here once the motor is properly set up and has been tested with a high voltage battery.		[https://openinverter.org/forum/viewtopic.php?p=69749#p69749 This initial set of parameters] have been used for successfull bench testing a motor with a pair of lead acid car batteries. Will update and eventually post a full set of parameters here once the motor is properly set up and has been tested with a high voltage battery.


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

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

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

2024-04-27T17:56:10Z

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

← Older revision		Revision as of 17:56, 27 April 2024
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	As of 18 April 2024, the following mods are required to use these boards:		As of 18 April 2024, the following mods are required to use these boards:

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

	Pinouts for the three connectors on this board below.		Pinouts for the three connectors on this board below.

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

2024-04-18T21:19:39Z

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

CJW: Added reference to forum thread

2024-04-12T11:24:01Z

Added reference to forum thread

← Older revision		Revision as of 11:24, 12 April 2024
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	'''Openinverter Parameters'''		'''Openinverter Parameters'''

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

CJW: Formatting

2024-04-12T11:22:26Z

Formatting

← Older revision		Revision as of 11:22, 12 April 2024
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	[[File:Ampseal board.png\|thumb\|300x300px\|Ampseal adapter board]]		[[File:Ampseal board.png\|thumb\|300x300px\|Ampseal adapter board]]
	A pair of adaptor boards (see images to right) are available and shipped with the current drop-in boards. These enable the ERNI Microbridge connector from the resolver to be connected to the required pins on the Ampseal connector. Design files for these boards will be posted on github at some point - if you need a copy in the meantime contact user 'CJW' or post on the i3 controller hacking thread.		A pair of adaptor boards (see images to right) are available and shipped with the current drop-in boards. These enable the ERNI Microbridge connector from the resolver to be connected to the required pins on the Ampseal connector. Design files for these boards will be posted on github at some point - if you need a copy in the meantime contact user 'CJW' or post on the i3 controller hacking thread.
	~~'''Code Update for Gate Driver Board - SPI Commication'''~~
	~~'''Code Update for Gate Driver Board - SPI Commication'''~~

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

← Older revision		Revision as of 16:34, 20 December 2024
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	# Motor temperature sensor to be mapped and added to code		# Motor temperature sensor to be mapped and added to code
	# Design files for adaptor boards posted to github		# Design files for adaptor boards posted to github
			[[Category:BMW]] [[Category:Inverter]]
	~~[[Category:OEM]]~~ [[Category:BMW]] [[Category:Inverter]]

← Older revision		Revision as of 18:44, 27 April 2024
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	https://openinverter.org/shop/index.php?route=product/product&product_id=72		https://openinverter.org/shop/index.php?route=product/product&product_id=72



Line 17:		Line 18:

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



Line 289:		Line 291:

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


	'''<big>Motor Resolver & Temperature Sensors</big>'''		'''<big>Motor Resolver & Temperature Sensors</big>'''
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	[[File:Mod 1. - Close SJ3.jpg\|thumb\|Mod 1. Close SJ3]]		[[File:Mod 1. - Close SJ3.jpg\|thumb\|Mod 1. Close SJ3]]



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

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


	'''Mod''' '''1. Close SJ3 on the openinverter board with solder'''		'''Mod''' '''1. Close SJ3 on the openinverter board with solder'''
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	[[File:Mod 5. - Gate driver PSU.jpg\|thumb\|Mod 5. - Gate driver PSU]]		[[File:Mod 5. - Gate driver PSU.jpg\|thumb\|Mod 5. - Gate driver PSU]]


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

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

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

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

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

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



Line 411:		Line 421:

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

← Older revision		Revision as of 21:19, 18 April 2024
Line 23:		Line 23:
	The drop-in board houses the openinverter, generates 32V for the gate driver board, communicates via SPI with the gate driver board to obtain voltage and temperature readouts, and provides outputs to operate contactors.		The drop-in board houses the openinverter, generates 32V for the gate driver board, communicates via SPI with the gate driver board to obtain voltage and temperature readouts, and provides outputs to operate contactors.

	As of 12 April 2024, the following mods are required to use these boards:		As of 18 April 2024, the following mods are required to use these boards:

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

	Pinouts for the three connectors on this board below.		Pinouts for the three connectors on this board below.
Line 400:		Line 401:
	List of tasks to be completed to enable full use of these motors:		List of tasks to be completed to enable full use of these motors:

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

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