Info on BMW hybrid battery packs?

[royhen99]

2020 gen2 pack.

[sprocketman]

I have a gen 1 BMW 330e F30 and I have purchased a gen 2 battery pack to try and get a better range.

Does anyone know the best way to use the gen 2 batteries in the gen 1 pack so that the car recognises it.
I tried plugging the blue plug into the s box unit with the new gen 2 batteries but the car wouldnt recognise the new batteries.THe pin out should be the same apart from the wire in pi4 which is not used on the Gen 1.

I dont want to cut all the ballance wires off each battery and join to the old BMS unit on the end of the battery. Because its a lot of work. the plugs to these are differant only the blue plug is the same.

[Venigo]

I have a gen 1 BMW 330e F30 and I have purchased a gen 2 battery pack to try and get a better range.

Does anyone know the best way to use the gen 2 batteries in the gen 1 pack so that the car recognises it.
I tried plugging the blue plug into the s box unit with the new gen 2 batteries but the car wouldnt recognise the new batteries.THe pin out should be the same apart from the wire in pi4 which is not used on the Gen 1.

I dont want to cut all the ballance wires off each battery and join to the old BMS unit on the end of the battery. Because its a lot of work. the plugs to these are differant only the blue plug is the same.

If the eos tester see's the new cells then it is only about registering the new cells in the sme box? As far as I know it takes first registering to the sme, the followed by ista.

[sprocketman]

Thank you for the reply Venigo I have ISTA but i dont have a EOS tester. Is it just BMW who have these?

[Gregski]

better late than never

the BMW hybrid BMS master module Gen 1 vs Gen 2

FYI: I was able to plug in the Gen 1 wire harness into the Gen 2 module

I plan on uploading pics of the Gen 1 and Gen 2 BMS wire harnesses next

part number comparison

[BHP4EVER]

I am working on bmw mini EV.....could someone help me out with a wiring diagram for the SME module please...I want to power the module up and gain diagnostics to it....i have a issue with 12 slave modules and no Can communictaion..

[Venigo]

Thank you for the reply Venigo I have ISTA but i dont have a EOS tester. Is it just BMW who have these?

No, you can buy these to.

Depends on the HV pack of the car:
- 81315A94550
- 83302353361
- 83302353250

Further good to know: the EOS security code can be generated online to.

[davefiddes]

Does anyone know what the resistance of the wire-wound pre-charge resistor is in these packs? It was mentioned a while back that they are KOA Speer Electronics BGR30 resistors but these can be anything from 10 to 390 ohms.

[sprocketman]

No, you can buy these to.

Depends on the HV pack of the car:
- 81315A94550
- 83302353361
- 83302353250

Further good to know: the EOS security code can be generated online to.

Hi, thanks you obviously know what your doing.
The only 10 digit numer on the HV pack name plate starts with 0211 and is under the manufacture date. is that it?
Can you point me in the direction of a site that can dothe code generation?
Thanks again.
Andrew

[sprocketman]

Does anyone know what the resistance of the wire-wound pre-charge resistor is in these packs? It was mentioned a while back that they are KOA Speer Electronics BGR30 resistors but these can be anything from 10 to 390 ohms.

They are 15 ohms on the first version of HV packs.

[cloudy]

Does anyone happen to have any vehicle side can logs from a BMW PHEV? I'm able to read out all parameters (SOC, temps,cell volts, power limits) from the intact SME, but am unable to close contactors and get a invalid qualifier status message from the balancing status. I think I need some vehicle messages to proceed... Thanks

[sprocketman]

I have done some teseting on the BMW battey connectors
I think the best way to use the newer 34Ah batteries in the old BMW hybrid packs is to swap the pins in the connectors and use the same BMS system.
There is a risk of shorting the cables so if you are doing this I recomend that the pins are swapped one at a time and double check before plugging back in.
I have included the pin outs of the two plugs below for info:-

[sprocketman]

Temperature valves are in ohms not volts

[mane2]

Safetybox/SBox HV Isolation meter!

Started going through can messages for how Safetybox reports HV isolation and found out that it actually has HV isolation meter and transmits info in message 0x600 (at least on BMW X5 Sbox). Data is presented in two pairs of bytes, one for HV- and one for HV+. Bytes 4 and 5 for HV- and bytes 6 and 7 for HV+.

First byte seems to be some value that increases when resistance goes down. Problem with this is that once you touch the connectors or have leak, this value changes when second byte changes.

Second byte is maybe the measuring scale/mode. By default when everything is ok, it seems to be 0x27 (no leaks) or 0x28 (small leak, hundreds of k Ohms). When shorted, I can see multiple different modes ranging from 0x23 to 0x2A. I didn't find any reasonable formula to figure this out.

This measuring works only when contactors are open.

So what I did, was just before doing precharge I'll check those bytes and if it's okay, do precharge + close all contactors. If not, raise an error flag.

Anyway, another nice feature that Sbox provides. I just hope someone is able to figure out more precise way to interpret those bytes. Would be cool to have exact isolation resistance figure.

Note, these values might be very different on your sbox and might be totally different with actual voltage. I tested with 121V from power supply but haven't yet checked in car with 360v nominal.

[mane2]

More info. So reading those bytes as 16 bit little endian to get value around 10000 when everything is ok. Once + or - value starts to deviate enough, there is a problem. SBox runs test cycle for -40v -> +40v with some logic, and this test cycle can take like 20-30 seconds. There seems to be some logic there when it tries to find the worst case. So reading one spot value does not tell you the truth. You can see that voltage going up and down from HV Out voltage sent by sbox. I ended up settings treshold for 800 (10000 -+ 800). Tested with resistors so that 10kOhm resistor fails the test and 220kOhm passes.

Code: Select all

CAN ID: 0x600
Length: 8 bytes
Format: 0x00 0x00 0x16 0xFF [B4] [B5] [B6] [B7]

- Bytes 0-3: Static header (always `00 00 16 FF`)
- Bytes 4-5 (B4-B5): OUT− (HV negative) channel raw data (16-bit little-endian)
- Bytes 6-7 (B6-B7): OUT+ (HV positive) channel raw data (16-bit little-endian)

## Data Interpretation

### Raw Values
- `raw_minus = (B5 << 8) | B4`  // 16-bit little-endian
- `raw_plus = (B7 << 8) | B6`   // 16-bit little-endian

### Baseline and Deviations
- **Baseline:** ~10000 
- **Deviation:** `abs(raw - 10000)`
- **Fault detection:** Based on maximum deviation during test cycle

### Safety Thresholds
- **Deviation threshold:** 800 (corresponds to ~150kΩ equivalent)
- **Fault condition:** Max deviation > 800

[cloudy]

Nice work! If it helps, also have isolation test/read working via original SME in battery emulator project...

There is also a "quality" score of the measurement //STAT_R_ISO_ROH_QAL_01_INFO Quality of measurement 0-21 (higher better)