BMW Hybrid Battery Pack: Difference between revisions

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In addition to the BMW 530e the same battery pack can be found in the 740e.  These battery packs consist of six battery modules. The same battery modules can be found in the 330e but in a smaller form factor made up of only five modules.
In addition to the '''BMW 5 Series (G30) 530e''' the same battery pack can be found in the '''7 Series (G12) 740e''' as well as the '''X Series''' '''(F15) X5'''.  These battery packs consist of six battery modules yielding 351 volts. The same battery modules can be found in the '''3 Series (F30) 330e''' but in a smaller form factor made up of only five modules and 293 volts.


[[File:Battery Location.jpg|thumb|The battery pack is located under the rear seat.]]
[[File:Battery Location.jpg|thumb|The battery pack is located under the rear seat.|alt=|none]]


== First Gen (-2018) ==


The Electrical Energy Storage System in the 530e as well as the 740e has a code name of SP06 and a capacity of 26 Ah.


== Second Gen (2019-present) ==


The newer SP41 high-voltage battery was installed in the G30 as well as the G12 Plug-in Hybrid Electric Vehicles starting in July of 2019. It has the same basic design as the SP06. The most significant change is the cell capacity increase from 26 Ah to 34 Ah.


 
== Technical Specifications ==
 
==== First Gen (-2018) ====
 
The SP06 has a capacity of 26 Ah.
 
==== Second Gen (2019-present) ====
 
The SP41 high-voltage battery was installed in the G30 Plug-in Hybrid Electric Vehicle starting in July of 2019. It has the same basic design as the SP06. The most significant change is the cell capacity increase from 26 Ah to 34 Ah.
 
==== Technical Specifications ====
{| class="wikitable"
{| class="wikitable"
|+
|+
!Technical data
!Technical data
!G30 PHEV (SP06)
!5 Series G30 PHEV (SP06)
-2018
-2018
!G30 PHEV (SP41)
!5 Series G30 PHEV (SP41)
2019-2022
2019-2022
!X5 G05 45e PHEV
2019-
|-
|-
|Voltage
|Voltage
|351.4 V (nominal voltage)
|351.4 V (nominal voltage)
|
|355 V (nominal voltage)
|354 V (nominal voltage)
|-
|-
|Voltage Range
|Voltage Range
|Min. 269 V – Max. 398 V
|Min. 269 V – Max. 398 V
|Min. 269 V – Max. 403 V
|
|
|-
|-
Line 37: Line 35:
|Lithium-ion
|Lithium-ion
|Lithium-ion
|Lithium-ion
|NCM811
|-
|-
|Number of battery cells
|Number of battery cells
|96 in series
|96 in series
|96 in series
|96 in series
|96 in series
|-
|-
|Number of cell modules
|Number of cell modules
|6
|6
|12
|-
|Cell voltage
|3.66 V
|3.70 V
|
|-
|Capacitance
|26 Ah
|34 Ah
|68Ah
|-
|Storable amount of energy
|9.2 kWh
|12 kWh
|24 kWh
|-
|Usable energy
|7.4 kWh
|10.4 kWh
|21.6 kWh (EU) / 17.06 kWh (US)
|-
|Max. power (discharge)
|83 kW (short-term)
|83 kW (short-term)
|50 kW continuous / 83kW peak
|-
|Maximum power (AC charging)
|3.7 kW
|3.7 kW
|3.7 kW
|-
|Weight
|248 lbs / 112.5 kg (without retaining brackets)
|261 lbs / 118.4kg (without retaining brackets)
|
|-
|Dimensions
|541 mm x 1134 mm x 271 mm
|541 mm x 1134 mm x 271 mm
|
|-
|Cooling system
|Refrigerant R1234yf
|Refrigerant R1234yf
|
|-
|Individual Module Dimensions
|364*183*110mm (L/W/H) without BMS attached
(add c. 25mm to length or height of module for BMS)
~13kg per module
|
|
|}
== Battery Management System, BMS ==
There is a SimpBMS version available on GitHub called '''BMWPhevBMS''' https://github.com/Tom-evnut/BMWPhevBMS created by Tome de Bree.
=== Wiring/pinouts ===
When using SimpBMS, the original BMW BMS master module should be unplugged (blue plug). This plug should instead be used to power the BMS slave modules and for the CAN connection to slave modules. See pinout below.
It's important to note that each plug in the wiring harness has an 'in' and an 'out' pin. I.e., the 5V, GND, and CAN connections are chained from one slave module to the next. So, if for some reason you have one of the slave modules unplugged, you may need to jumper the pins in that plug or else the modules further down the chain may not work.
[[File:BMW 5 Modules Pack.jpg|thumb|397x397px|Location of Blue Connector on Battery Master 5 module pack]]
[[File:BMW 6 Module pack.jpg|thumb|398x398px|Location of Blue Connector on Battery Master 6 module pack]]
{| class="wikitable"
|+Blue plug pinout
!Pin
!Function
!Note
|-
|1
|CAN H
|
|-
|2
|CAN L
|
|-
|3
|
|
|
|
|-
|-
|Cell voltage
|4
|
|
|-
|5
|5V
|Apply 5V here to power the slave modules
|-
|6
|GND
|
|-
|7
|CAN H
|
|-
|8
|CAN L
|
|-
|9
|
|
|-
|10
|
|
|
|
|-
|-
|Capacitance
|11
|5V
|Apply 5V here to power the slave modules
|-
|12
|GND
|
|}
 
{| class="wikitable"
|+Gen 2 Blue plug pinout
!Pin
!Function
!Note
|-
|1
|CAN L
|
|
|-
|2
|CAN H
|
|
|-
|-
|Storable amount of energy
|3
|
|
|
|-
|4
|Interlock
|All Modules connected, 5V. Not connected, float.
|-
|5
|5V
|Apply 5V here to power the slave modules
|-
|6
|GND
|
|
|-
|-
|Usable energy
|7
|
|
|
|
|-
|-
|Max. power (discharge)
|8
|
|
|
|
|-
|-
|Maximum power (AC charging)
|9
|
|
|
|
|-
|-
|Weight
|10
|
|
|
|
|-
|-
|Dimensions
|11
|
|
|
|
|-
|-
|Cooling system
|12
|
|
|
|
|}
|}


 
== Part Numbers<ref>Forum Reference: https://openinverter.org/forum/viewtopic.php?f=20&t=709</ref> ==
 
==== Part Numbers ====
and here's how the six cell modules are connected together with the high voltage orange wires
and here's how the six cell modules are connected together with the high voltage orange wires
[[File:High Voltage Cables.jpg|thumb|High Voltage Cables]]
[[File:High Voltage Cables.jpg|thumb|High Voltage Cables|alt=|none]]




Line 110: Line 246:


<nowiki>#</nowiki>8 Part Number: 61278650793 External Connector Negative
<nowiki>#</nowiki>8 Part Number: 61278650793 External Connector Negative
=== Pinout - Main battery connector ===
=== Pin assignments at plug connector A332*1B ===
{| class="wikitable"
!Pin
!Type
!Description /Signal type
!Connection /Measuring information
|-
|1
|E
|Supply, terminal 30
|Power distribution box, rear
|-
|2
|E
|High-voltage interlock loop signal
|Electric-machine electronics
|-
|3
|E
|Terminal 30c signal
|Connector, terminal 30C
|-
|4
| --
|Not used
|
|-
|5
| --
|Not used
|
|-
|6
| --
|Not used
|Yellow/Green wire inside battery - Use unknown
|-
|7
| --
|Not used
|
|-
|8
| --
|Not used
|
|-
|9
| --
|Not used
|
|-
|10
|A
|Supply
|Refrigerant shutoff valve, high-voltage battery unit
|-
|11
|A
|Activation
|Refrigerant shutoff valve, high-voltage battery unit
|-
|12
|M
|Ground
|Ground point
|-
|13
|E/A
|K-CAN bus signal L
|K-CAN5 bus connection
|-
|14
|E/A
|K-CAN bus signal H
|K-CAN5 bus connection
|-
|15
| --
|K-CAN bus signal L
|Put a 120Ohm resistor across these to terminate pack
|-
|16
| --
|K-CAN bus signal H
|Put a 120Ohm resistor across these to terminate pack
|-
|17
| --
|Not used
|
|-
|18
| --
|Not used
|
|-
|19
| --
|Not used
|
|-
|20
| --
|Not used
|
|-
|21
| --
|Not used
|
|-
|22
| --
|Not used
|
|-
|23
|E
|High-voltage interlock loop signal
|High-voltage safety connector
|-
|24
| --
|Not used
|
|}
=== Temperature Sensors ===
The temperature sensors used in the hybrid battery packs are NTC 100k/4.4 and 10k/3.4 <ref>Forum Reference: https://openinverter.org/forum/viewtopic.php?p=36640#p36640</ref>.
=== S-Box ===
The BMW Hybrid Battery Pack contains a module that contains contactors and a shunt which is known as a Control Unit Module Security Fuse Box, S-Box PHEV BK, or S-Box that is now supported by the ZombieVerter. There are S-Boxes available in a number of the BMW PHEV models.
[[File:BMW S-box.jpg|alt=BMW S-Box|thumb|453x453px|BMW S-Box]]
Part numbers include 8686893, 8638197, 8651068, 8681536, 8844217, 9470054, 9846612, found in the following PHEV models:
* 2 Series F45 Active Tourer LCI
* 3 Series G20
* 3 Series G20 LCI
* 3 Series G21
* 3 Series G21 LCI
* 5 Series G30
* 5 Series G30 LCI
* 5 Series G31 LCI
* 5 Series G38
* 5 Series G38 LCI
* [[File:SBOX.jpg|thumb|BMW S-Box High voltage connection]]7 Series G11 LCI
* 7 Series G12 LCI
* X1 F48 LCI
* X1 F49
* X1 F49 LCI
* X2 F39
* X3 G01
* X3 G01 LCI
* X5 F15
* X5 G05
* MINI Countryman F60
* MINI Countryman F60 LCI
Damien's notes:
Four heavy duty spade terminals provide connection for HV Battery + , - and Output + ,-
Connection of Can data and 12v power is via a white 16 pin connector on the front.
Pins 12 and 14 to +12v
Pin 3 to GND
Pin 1 CANH
Pin 10 CANL
CAN is 500K speed.
Two ids are required to run the SBox and control its contactors:
0x100 and 0x300 DLC 4 at 20ms intervals.
0x100 has a counter and CRC8 and is the main control message.
Byte 0 controls contactor function as follows :
0x62 Activates negative contactor
0x0A Activates positive contactor
0x8A Activates positive contactor and precharge relay
0xA6 Activates negative contactor and precharge relay
0x62 Activates negative and positive contactors and precharge relay
0x86 Activates precharge relay only.
Other combinations of bits in byte 0 will cause individual contactors and combinations of contactors and precharge relay to engage.
Byte 1: Counter in upper nibble running from 0x0 to 0xE. Lower nibble fixed at 0x1.Function not yet investigated.
Byte 2: fixed at 0xFF. Function not yet investigated.
Byte 3: CRC8 , Poly 0x31 ,Initial value 0x00, final XOR 0x00 , inverse both. Calculated on length of 8 bytes while message is only 4 bytes long.
0x300 can be static:
0xFF , 0xFE , 0xFF , 0xFF
Information such as Battery voltage, Current, Output voltage etc are provided over CAN making it a very versatile unit. Messages for Ah,kwh,kw etc are being investigated.
More information is available on Damien's GitHub - https://github.com/damienmaguire/BMW_SBox
== Connectors ==
=== HV-Connectors ===
<nowiki>#</nowiki>1 Part Number: 61278621016 Main Negative (runs from Cell Module #1 to the Safety Box #8 front connector)
<nowiki>#</nowiki>5 Part Number: 61278621020 Main Positive (runs from Cell Module #6 to the Safety Box #7 front connector)
=== Communication Connector (white)<ref>https://openinverter.org/forum/viewtopic.php?p=66855&hilit=s+box+connector&sid=d184248a3982361d3e4911311bce9089#p66855</ref> ===
Connector is made by TE Connectivity
Housing 965778-1
BMW 8-364-666
Cover 2-967416-1
BMW 8-364-656
Terminal for 0.5 - 0.75mm2 963715-1
== Disassembly (Do at own risk) ==
There is a video where a phev pack is dissembled  it is not definitive and would recommend reading guide for VW Phev batteries first, [[VW Hybrid Battery Packs]].
https://youtu.be/RQsX6E2CdXo?si=flltJuqvkzZl_GpC ( 20:00 to 22:30 be warned there is arse cleavage near the end of that clip)
== References ==
<references />
[[Category:OEM]] [[Category:BMW]] [[Category:Battery]]

Latest revision as of 14:20, 25 August 2024

In addition to the BMW 5 Series (G30) 530e the same battery pack can be found in the 7 Series (G12) 740e as well as the X Series (F15) X5. These battery packs consist of six battery modules yielding 351 volts. The same battery modules can be found in the 3 Series (F30) 330e but in a smaller form factor made up of only five modules and 293 volts.

The battery pack is located under the rear seat.

First Gen (-2018)

The Electrical Energy Storage System in the 530e as well as the 740e has a code name of SP06 and a capacity of 26 Ah.

Second Gen (2019-present)

The newer SP41 high-voltage battery was installed in the G30 as well as the G12 Plug-in Hybrid Electric Vehicles starting in July of 2019. It has the same basic design as the SP06. The most significant change is the cell capacity increase from 26 Ah to 34 Ah.

Technical Specifications

Technical data 5 Series G30 PHEV (SP06)

-2018

5 Series G30 PHEV (SP41)

2019-2022

X5 G05 45e PHEV

2019-

Voltage 351.4 V (nominal voltage) 355 V (nominal voltage) 354 V (nominal voltage)
Voltage Range Min. 269 V – Max. 398 V Min. 269 V – Max. 403 V
Battery cells Lithium-ion Lithium-ion NCM811
Number of battery cells 96 in series 96 in series 96 in series
Number of cell modules 6 6 12
Cell voltage 3.66 V 3.70 V
Capacitance 26 Ah 34 Ah 68Ah
Storable amount of energy 9.2 kWh 12 kWh 24 kWh
Usable energy 7.4 kWh 10.4 kWh 21.6 kWh (EU) / 17.06 kWh (US)
Max. power (discharge) 83 kW (short-term) 83 kW (short-term) 50 kW continuous / 83kW peak
Maximum power (AC charging) 3.7 kW 3.7 kW 3.7 kW
Weight 248 lbs / 112.5 kg (without retaining brackets) 261 lbs / 118.4kg (without retaining brackets)
Dimensions 541 mm x 1134 mm x 271 mm 541 mm x 1134 mm x 271 mm
Cooling system Refrigerant R1234yf Refrigerant R1234yf
Individual Module Dimensions 364*183*110mm (L/W/H) without BMS attached

(add c. 25mm to length or height of module for BMS)

~13kg per module

Battery Management System, BMS

There is a SimpBMS version available on GitHub called BMWPhevBMS https://github.com/Tom-evnut/BMWPhevBMS created by Tome de Bree.

Wiring/pinouts

When using SimpBMS, the original BMW BMS master module should be unplugged (blue plug). This plug should instead be used to power the BMS slave modules and for the CAN connection to slave modules. See pinout below.

It's important to note that each plug in the wiring harness has an 'in' and an 'out' pin. I.e., the 5V, GND, and CAN connections are chained from one slave module to the next. So, if for some reason you have one of the slave modules unplugged, you may need to jumper the pins in that plug or else the modules further down the chain may not work.

Location of Blue Connector on Battery Master 5 module pack
Location of Blue Connector on Battery Master 6 module pack
Blue plug pinout
Pin Function Note
1 CAN H
2 CAN L
3
4
5 5V Apply 5V here to power the slave modules
6 GND
7 CAN H
8 CAN L
9
10
11 5V Apply 5V here to power the slave modules
12 GND
Gen 2 Blue plug pinout
Pin Function Note
1 CAN L
2 CAN H
3
4 Interlock All Modules connected, 5V. Not connected, float.
5 5V Apply 5V here to power the slave modules
6 GND
7
8
9
10
11
12

Part Numbers[1]

and here's how the six cell modules are connected together with the high voltage orange wires

High Voltage Cables


#1 Part Number: 61278621016 Main Negative (runs from Cell Module #1 to the Safety Box #8 front connector)

#2 Part Number: 61278621017 Connects Cell Module #2 to Cell Module #3

#3 Part Number: 61278621018 Connects Cell Module #3 to Cell Module #4

#4 Part Number:61278621019 Connects Cell Module #4 to Cell Module #5

#? Part Number:??????????? Connects Cell Module #5 to Cell Module #6

#5 Part Number: 61278621020 Main Positive (runs from Cell Module #6 to the Safety Box #7 front connector)

#6 Part Number: 61278618444 Connects Cell Module #1 to Cell Module #2

===========================================================

#7 Part Number: 61278650791 External Connector Positive

#8 Part Number: 61278650793 External Connector Negative

Pinout - Main battery connector

Pin assignments at plug connector A332*1B

Pin Type Description /Signal type Connection /Measuring information
1 E Supply, terminal 30 Power distribution box, rear
2 E High-voltage interlock loop signal Electric-machine electronics
3 E Terminal 30c signal Connector, terminal 30C
4 -- Not used
5 -- Not used
6 -- Not used Yellow/Green wire inside battery - Use unknown
7 -- Not used
8 -- Not used
9 -- Not used
10 A Supply Refrigerant shutoff valve, high-voltage battery unit
11 A Activation Refrigerant shutoff valve, high-voltage battery unit
12 M Ground Ground point
13 E/A K-CAN bus signal L K-CAN5 bus connection
14 E/A K-CAN bus signal H K-CAN5 bus connection
15 -- K-CAN bus signal L Put a 120Ohm resistor across these to terminate pack
16 -- K-CAN bus signal H Put a 120Ohm resistor across these to terminate pack
17 -- Not used
18 -- Not used
19 -- Not used
20 -- Not used
21 -- Not used
22 -- Not used
23 E High-voltage interlock loop signal High-voltage safety connector
24 -- Not used

Temperature Sensors

The temperature sensors used in the hybrid battery packs are NTC 100k/4.4 and 10k/3.4 [2].

S-Box

The BMW Hybrid Battery Pack contains a module that contains contactors and a shunt which is known as a Control Unit Module Security Fuse Box, S-Box PHEV BK, or S-Box that is now supported by the ZombieVerter. There are S-Boxes available in a number of the BMW PHEV models.

BMW S-Box
BMW S-Box

Part numbers include 8686893, 8638197, 8651068, 8681536, 8844217, 9470054, 9846612, found in the following PHEV models:

  • 2 Series F45 Active Tourer LCI
  • 3 Series G20
  • 3 Series G20 LCI
  • 3 Series G21
  • 3 Series G21 LCI
  • 5 Series G30
  • 5 Series G30 LCI
  • 5 Series G31 LCI
  • 5 Series G38
  • 5 Series G38 LCI
  • BMW S-Box High voltage connection
    7 Series G11 LCI
  • 7 Series G12 LCI
  • X1 F48 LCI
  • X1 F49
  • X1 F49 LCI
  • X2 F39
  • X3 G01
  • X3 G01 LCI
  • X5 F15
  • X5 G05
  • MINI Countryman F60
  • MINI Countryman F60 LCI

Damien's notes:

Four heavy duty spade terminals provide connection for HV Battery + , - and Output + ,-

Connection of Can data and 12v power is via a white 16 pin connector on the front.

Pins 12 and 14 to +12v

Pin 3 to GND

Pin 1 CANH

Pin 10 CANL

CAN is 500K speed.

Two ids are required to run the SBox and control its contactors:

0x100 and 0x300 DLC 4 at 20ms intervals.

0x100 has a counter and CRC8 and is the main control message.

Byte 0 controls contactor function as follows :

0x62 Activates negative contactor

0x0A Activates positive contactor

0x8A Activates positive contactor and precharge relay

0xA6 Activates negative contactor and precharge relay

0x62 Activates negative and positive contactors and precharge relay

0x86 Activates precharge relay only.

Other combinations of bits in byte 0 will cause individual contactors and combinations of contactors and precharge relay to engage.

Byte 1: Counter in upper nibble running from 0x0 to 0xE. Lower nibble fixed at 0x1.Function not yet investigated.

Byte 2: fixed at 0xFF. Function not yet investigated.

Byte 3: CRC8 , Poly 0x31 ,Initial value 0x00, final XOR 0x00 , inverse both. Calculated on length of 8 bytes while message is only 4 bytes long.

0x300 can be static:

0xFF , 0xFE , 0xFF , 0xFF

Information such as Battery voltage, Current, Output voltage etc are provided over CAN making it a very versatile unit. Messages for Ah,kwh,kw etc are being investigated.

More information is available on Damien's GitHub - https://github.com/damienmaguire/BMW_SBox

Connectors

HV-Connectors

#1 Part Number: 61278621016 Main Negative (runs from Cell Module #1 to the Safety Box #8 front connector)

#5 Part Number: 61278621020 Main Positive (runs from Cell Module #6 to the Safety Box #7 front connector)

Communication Connector (white)[3]

Connector is made by TE Connectivity

Housing 965778-1

BMW 8-364-666

Cover 2-967416-1

BMW 8-364-656

Terminal for 0.5 - 0.75mm2 963715-1

Disassembly (Do at own risk)

There is a video where a phev pack is dissembled it is not definitive and would recommend reading guide for VW Phev batteries first, VW Hybrid Battery Packs.

https://youtu.be/RQsX6E2CdXo?si=flltJuqvkzZl_GpC ( 20:00 to 22:30 be warned there is arse cleavage near the end of that clip)

References

  1. ↑ Forum Reference: https://openinverter.org/forum/viewtopic.php?f=20&t=709
  2. ↑ Forum Reference: https://openinverter.org/forum/viewtopic.php?p=36640#p36640
  3. ↑ https://openinverter.org/forum/viewtopic.php?p=66855&hilit=s+box+connector&sid=d184248a3982361d3e4911311bce9089#p66855
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