The SuperYacht BMW E65 7 Series

[Jack Bauer]

In today's SuperYacht adventures we cut the cord on the old fuel system, powerwash several kg of dirt out of the wheel well and get a donation of an EU Model 3 charge port and ecu for some CCS fun:)

[Jack Bauer]

Now for the simple part : force feeding a Tesla Model 3 EU CCS charge port down the filler neck of a 20 year old 7 series....

In other news the front battery box assembly is done. Getting my head around the OI bms now. Pro tip : trying to compile 8 bit avr c code with a 32 bit arm compiler is a bad idea

[mdrobnak]

Now for the simple part : force feeding a Tesla Model 3 EU CCS charge port down the filler neck of a 20 year old 7 series....

I hope the US version fits a little better than that..I'll be honest, I didn't measure the E46 opening before going down this path.

In other news the front battery box assembly is done. Getting my head around the OI bms now.

What is being used to compress the cells together? Don't prismatic cells need some help staying in the correct shape?

Pro tip : trying to compile 8 bit avr c code with a 32 bit arm compiler is a bad idea

That made laugh quite a bit this morning.

Hopefully we'll get this thing charging rapidly. (See what I did there? )

-Matt

[johu]

I thought fitting ChaDeMo was hard, but this Though for some reason I think you will force it in anyway

[Jack Bauer]

First success today with the Openinverter bms. 8 of the 25 boards fitted and talking in the front battery. Can't wait for the youtube comments when they see me working away with bare hands, no flash suit and no $$$ orange tools

[ZooKeeper]

Can't wait for the youtube comments when they see me working away with bare hands, no flash suit and no $$$ orange tools

Just tell them you have developed "internal resistance" to electrons... :O

[jalovick]

Can't wait for the youtube comments when they see me working away with bare hands, no flash suit and no $$$ orange tools

I believe it goes "Damien, you're doing it wrong"...

Funnily enough, I'd just posted about PPE on the DIY Electric Vehicles Facebook page with the obligatory link to WeberAuto's PPE video, as there are a stack of new people joining, and I figure they need to at least be aware of the potential dangers. It has sparked quite a conversation.

For someone like you, working on these systems is old hat. I will say be careful, as always...

Jamie

[mdrobnak]

For someone like you, working on these systems is old hat. I will say be careful, as always...

^ This. I've made more errors in my job due to (being real here) complacency. Just because it's gone fine the previous 100 times doesn't mean we don't want to try and do it right on run 101. Damien is quite capable, hopefully he ensures he'll be around for a while still.

-Matt

[LRBen]

I have a question on your new battery pack, are you planning on running those cells all in series? Or were you going to parallel the front and back boxes?
I'm kind of hesitant to parallel strings of cells, but I'm also a little hesitant to reconfigure my Kokam cells away from the 10s1p modules they came in.

[Jack Bauer]

Front and rear packs will be in parallel. 100s in each pack so 100s2p.

[LRBen]

That's interesting, I was lead to believe that parallel strings are best to be avoided. But I'm not going to argue, seemed a shame/lots of effort to undo the work that went into those 10s modules!

[slow67]

Smith Electric trucks used Valence batteries in parallel. Separate fuses, bmses, and contactors for each string.

[rstevens81]

I always thought that the not in parralell thing was only to be avoided where the packs would have different capacities , whereby one would discharge faster than the other and you would get current 'sloshing' back and forth between the packs whilst the voltages would try and settle.
However I by no means an expert so I could be wrong.

Edited, not completely correct, parralell strings must essentially independent with own contactors etc.
Added Orion pdf on subject

parallel_strings.pdf

(398.43 KiB) Downloaded 365 times

[ggeter]

After a long absence the SuperYacht is back home. Drove today with the same crappy batteries but oh my god it is a BEAST! Clocked 90mph at 5500rpm on MG2 with the battery sagged to under 300v and it was still pulling!

Thanks to an amazing donation from a customer I have a 40kwh pack of Kokam cells that will be fitted soon.

What gear do you usually run in? Do you shift at all, or just go in high gear only?

[shirk]

Just read this whole thread start to finish. Great project.

Did Bexus ever end up on a dyno?

This gs450h set up has me wanting to do an e46 wagon project.

[Domt177]

Just read this whole thread start to finish. Great project.

Did Bexus ever end up on a dyno?

This gs450h set up has me wanting to do an e46 wagon project.

That’s precisely what I’m up to, e46 touring with gs450h gearbox

[Jack Bauer]

I'm calling it the middle class man's charger:) Ampera charger kindly sent to me by Boxsterev , a nissan micra radiator and some left over bits and pieces. doubles as a 3.3kw 200-420vdc power supply also.

Anyway, getting down to charging and balancing the front battery pack for the E65 now that I have a "portable" charger:)

[Boxster EV]

Haha. That’s very cool. Done well that charger.

[james@N52E01]

Never say die! Very smart little unit. Are you going to bottom balance the cells with a managed system or manually? Asking for a friend

[tom91]

Reminds me of my little setup also using a Ampera charger to charge the random things i build.



And ofcourse mine also had smashed off connectors.

[bobbyj_408]

Reminds me of my little setup also using a Ampera charger to charge the random things i build.

And ofcourse mine also had smashed off connectors.

Nice! Tom, looks like you're connecting the charger to the wall outlet directly for testing, is that correct? I'm guessing you're input would be 220v AC, but 110v (US) should work, right?

[tom91]

Reminds me of my little setup also using a Ampera charger to charge the random things i build.

And ofcourse mine also had smashed off connectors.

Nice! Tom, looks like you're connecting the charger to the wall outlet directly for testing, is that correct? I'm guessing you're input would be 220v AC, but 110v (US) should work, right?

Should work, I have not proven it myself.

[bobbyj_408]

Should work, I have not proven it myself.

Thank you!

[Jack Bauer]

Got some new battery plans for the E65:)

[arturk]

Nice looking modules Damien (Jaguar I-Pace?). I wonder if you can fit all 36 modules in E65. That would be awesome.