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Understanding the LED boards
White board The most simple design. This board consists of 5 LED's with series limiting resistor...
Troubleshooting broken companion boards
Three boards 76, failed in Stale's battery in the field - does not run LEDs, SOC output is wro...
Test procedure for early prototypes
After assembly, each board needs to be tested and approved before it may be used in a battery. Th...
Initial planning for companion boards
One tiny board of 4 cm times 2 cm with 3 terminals: Battery positive Battery negative SOC ou...
Installing the v6 board
Three known problems The ZXTR2012Z voltage regulator cannot handle the battery voltage suddenl...
Flat 36V batteries with green 'sandwich' BMS
These BMSs have the LEDs and the button built in, not on a separate board - making our life more ...
Interface pinouts
Flat with white BMS board Orange wire No GND path to the connector, then no NTC taken to the ...
Finding the PCB connectors
For the very final version of the BH board, we need to integrate all connectors that make it comp...
DC/DC converter and LDO evaluation
The single most expensive components in our boards are the RECOM DC/DC converters. 55 kr/pcs. Ou...
Brose BH hack
Mapping the pins Compared to black: only noise everywhere Compared to brown: Orange: 9.72V...
Troubleshooting: Output oscillations
The SOC output had a lot of noise on it, causing the displayed percentage on the display to move ...
Basic idea: SoC indication hack
The BMS makes a 0-10V signal, that is interpreted by the display as state-of-charge in a linear w...
Avoiding hangups
Problem description We see that the smart SOC boards can 'hang up' either by themselves, or if t...
VW e-Golf modules, 2nd generation, 111 Ah
Small module Pinout: B1 = pin 7 B2 = pin 3 Temp1 = pin 6 Temp 2 = pin 1 There is no groun...
Cutting the main boards
The main boards were made of 18mm thick pine boards cut on a CNC mill at Fellesverkstedet. Painte...
BMS settings
The BMS is a Daly Smart BMS with Bluetooth, Li-ion 12S 80A. One must connect to the BMS via th...
Plugs
The original chargers used the Lester 21486 connector. This connector has three pins, and is real...
Prototype building
Cleaning Building The 2nd generation VW modules The smart modules do not show the ...
Bill of materials
Quantity Price per unit w/o MVA VW e-Golf big module 3 20...