Z3 EV Conversion

[Andybpowell]

In all honesty I can't argue with you I just liked the simplicity of my way keeping it all in one place but logically having a permanent live cable running under the car is not Ideal even if it is fused
So this is one of the reasons I'm posting all of this so someone can talk me out of doing things that seem like a good idea at the time sometimes I can be a bit focused and not see the big picture

 

[Tom Cheesewright]

So this is one of the reasons I'm posting all of this so someone can talk me out of doing things that seem like a good idea at the time sometimes I can be a bit focused and not see the big picture

Ha! It is a ballache but I'm hoping to reuse the old S-box at the remote end and I've built some extra contactors into my junction box for the inbound side. That's the bit I forgot initially: of course you have to isolate it at both ends.

 

[Andybpowell]

I've gone over to local contactors so at least I won't have to isolate at both ends as it will disable the contactors if i unplug the cable from either end

 

[Andybpowell]

This is the revised front battery box just containing the contactors for the front battery instead of front and rear, I've fittted a perspex cover over the premanent live parts to improve safety the BMS is fitted, the can bus current sensor is fitted and it also now has a connection block for the rear battery box and the charger to connect

and most importantly it's in the car

I do have a slight issue with the brake booster pump being in the way but that's pretty minor

 

[Tom Cheesewright]

This is the revised front battery box just containing the contactors for the front battery instead of front and rear, I've fittted a perspex cover over the premanent live parts to improve safety the BMS is fitted, the can bus current sensor is fitted and it also now has a connection block for the rear battery box and the charger to connect

View attachment 232759

and most importantly it's in the car

View attachment 232761

View attachment 232763

View attachment 232765

I do have a slight issue with the brake booster pump being in the way but that's pretty minor

Looking good!

 

[Duncodin]

So will the connection between the rear box and front box be live when the 12v is off?

Why is permant live a problem? When the car is 'off' and stationary then damage or movement to the underside is unlikely. Any damage is going to happen, if ever, when the car is 'on' and moving?

Mind you. I don't know what I'm talking about so don't listen to me.

 

[Andybpowell]

Why is permant live a problem? When the car is 'off' and stationary then damage or movement to the underside is unlikely. Any damage is going to happen, if ever, when the car is 'on' and moving?

Mind you. I don't know what I'm talking about so don't listen to me.

You're correct in what you say but it's more about good practice, also if they decide to regulate such conversions at some point then it might become more so doesn't hurt anything other than my OCD to do it.

 

[Tom Cheesewright]

[

Why is permant live a problem? When the car is 'off' and stationary then damage or movement to the underside is unlikely. Any damage is going to happen, if ever, when the car is 'on' and moving?

Mind you. I don't know what I'm talking about so don't listen to me.

It's more about working on it - you, a mechanic or (worst case) emergency services. It's good to know that - barring contactors welding closed - if the key is out, there's no HV floating around.

 

[Duncodin]

It's more about working on it - you, a mechanic or (worst case) emergency services. It's good to know that - barring contactors welding closed - if the key is out, there's no HV floating around.

That's it. I have no idea how high HV is. If it's squillions of volts/amps then I'd also be wanting it off most of the time as well. Like I said. I don't know what I'm talking about - but eager, and quick, to learn.

 

[Nodzed]

This thread just blows me away .............. incredible.

 

[Tom Cheesewright]

That's it. I have no idea how high HV is. If it's squillions of volts/amps then I'd also be wanting it off most of the time as well. Like I said. I don't know what I'm talking about - but eager, and quick, to learn.

Typically around 400V and potentially a few hundred amps. It's toast territory!

 

[Ianmc]

Assume you need a HV "ticket" to install such?

 

[Tom Cheesewright]

Assume you need a HV "ticket" to install such?

Nope. Not yet. I suspect there will be tighter regulation in the years ahead but it's a bit of a wild west at the moment.

 

[Ianmc]

Nope. Not yet. I suspect there will be tighter regulation in the years ahead but it's a bit of a wild west at the moment.

Blimey.

 

[t-tony]

Nope. Not yet. I suspect there will be tighter regulation in the years ahead but it's a bit of a wild west at the moment.

Regulation will come when an MOT tester gets electrocuted In the end you don’t have to be a time served plumber to fit a tap washer, but maybe some should.

Tony.

 

[Ianmc]

In the end you don’t have to be a time served plumber to fit a tap washer, but maybe some should.

The consequences of none SQEP HV installation are rather more severe.

 

[Tom Cheesewright]

Regulation will come when an MOT tester gets electrocuted In the end you don’t have to be a time served plumber to fit a tap washer, but maybe some should.

Tony.

I'd actually like there to be a bit more regulation, like an enhanced MOT for example. Doesn't need a full IVA for a simple motor swap, but some safety checks on the HV and mounting would be sensible.

 

[t-tony]

The consequences of none SQEP HV installation are rather more severe.
[/QUOTE]

My remarks were ”tongue in cheek” I thought you might have realised?

Tony.

 

[t-tony]

I'd actually like there to be a bit more regulation, like an enhanced MOT for example. Doesn't need a full IVA for a simple motor swap, but some safety checks on the HV and mounting would be sensible.

For an ICE conversion when it comes to an MOT the tester is required to make sure it has been done correctly but as of now Testers don’t have enough knowledge or training to be able to make those type of decisions on an Electric Motor conversion, so personally I think an SVA test would be sensible.

Tony.

 

[Andybpowell]

It's been nearly a couple of weeks since my last update and the car doesn't look much differant but like lots of car projects a lot of the time and effort is buried away in it's innards
all of the High Voltage wiring is complete

the low voltage wiring is all in place and just needs connecting ( just ) I've made a mounting plate up to go where the ecu went which has the three main boards on it this is two of them

and this is the third which I've just remade to incorporate some things I hadn't thought of

this final board is the only one which will be powered permanently this will monitor the charging socket, ignition live and contactors and decide what needs to be powered up it also controls the power to the switched live relay,power steering relay and coolant pump using PWM control where possible to reduce power consumption