DIY Charging Supply PSU for ISTA+ BMW Programming

fmorelli

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I've been working with @Seb335i to set up a programming environment at my place. As we've proceeded we got the point of using ISTA+ to program, and of course my battery charger doesn't cut the mustard. ISTA+ wants to see 13V maintained. Some programming activities can take a long time, and maintaining charge is an issue. BMW recommends a variety of pieces of equipment - a good reference point is the Duetronics DBL 1200 and 1600. These are 80-90A units. Schumacher, another good company, makes the flash reprogrammer/charger INC100. We are talking solutions that are in the $1,000+ range for the BMW approved Deutronics (not too common in the USA, btw) and the Schumacher can be found for about $700 shipped.

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Not wanting to plunk this kind of cash down, I started to consider other solutions with Sebastian. We found people making chargers with server power supply units (PSU), but information for the BMW application was thin. The RC crowd has used such PSU's for years to charge LiPo batteries for various RC vehicles and planes. (here's an 11-year-old active thread, 300 pages deep on the RC forums!)

Thankfully Jim (@NoQuarter) was intrigued enough and willing to undertake this project with me. In fact, he's taken the lead on it with my helping out. So I'm considering this more his baby with my instigating and then trying to pitch in from the back seat. Unlike most of the solutions we saw, Jim and I set out to put together a DIYable solution that is elegant, compact, reliable, and cost effective. We've gotten far enough along that we want to start sharing information. When we are done there will be all the DIY things one desires - parts list, explanations where needed, etc. Our target cost is $200. One can cut corners and spend less than this to get a functioning solution - once we publish the parts list and such it will be pretty evident where one can reduce cost if that's a factor.

Please note this is not done at this point and is a work in progress. We expect to have working examples in a few weeks, and will post here as we go along. Here's the build sheet:


Filippo
 
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fmorelli

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So the design of the charger - it will be encased in a 4800 series case (remember to always use the Harbor Freight Coupon Database for discounts). These are relatively inexpensive and quite sturdy. All displays, cabling, and controls will be mounted on the sides. With a false bottom one will be able to store both the charging cables and wall cable inside the case when not in use. The unit will be able to operate with the case closed, so easy to stick wherever while operating. Of course the foam will be removed from the bottom.

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@NoQuarter selected the PSU which powers thea Dell R900 server . These power supplies are built for serious duty use with lots of internal failsafes. Specifically the Dell D1570P. Note there are a variety of alternate numbers for this class of Dell PSU. As well, one can explore a variety of other alternate PSUs. This specific unit can be run on a 15A 110AC circuit, and is capable of producing up to 90A output and ~14V. Here's a spec sheet, and a variety of photos of the PSU.
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aus335iguy

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Im contemplating creating a similar environment so i can update and flash various modules. I had bought a power supply online previously but by the time it had arrived it had no corners thanks to the shipping company. In for the result!!!
 

fmorelli

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Im contemplating creating a similar environment so i can update and flash various modules. I had bought a power supply online previously but by the time it had arrived it had no corners thanks to the shipping company. In for the result!!!
Ouch. Bummer. We're still in the throws of a few details. Jim has taken the lead on the first version, with some parts in and others coming. Ditto for me. We will both post as we have info to share. I'm expecting we'll have working versions in the next couple weeks.

Filippo
 
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fmorelli

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NoQuarter

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A surprise to us both was the difficulty in sorting out the C13 power inlet. Finding a quality one with a switch and properly rated for the full 15amps was a chore.

Another task still ahead is making a connection to the 5 spade DC power side that is reliable and can maintain 80amps.

Jim
 

fmorelli

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One would think this was easier than it has been - but I suppose all projects seem to go that way, at least for me! We wanted to manage cost and still arrive at a functional, reliable, and somewhat elegant solution. After a short while it became pretty clear that $200 was a high-side target for the project. Parts simply add up.

One thing we discussed at length was having decent quality parts in the power path. The Dell PSU is excellent by all accounts, for example. The power path has a AC and DC side: we chose Schurter for the plugs and switches on the AC side. On the DC side there was a lot of back and forth - we liked the idea of using welding couplers to supply charging power (this is how the Deutronics is done, for example). In the end we chose Anderson Power Products (PowerWerx) to make the AC side connection.

To Jim's point on making the DC side connections to the PSU, Jim took a very pass by make a customer connector with aluminum. We went searching for spades which we could co-opt but nothing of the right size surfaced. We could not find a corresponding male connector to the PSU, which we would have like to have started from and modified. At this point we've decided to simply make our own copper spades to size, drill them to 10awg, and gang them into a 5 spade connector. Maybe a more off-the-shelf solution will become evident. in the meantime this will be copper, relatively inexpensive and easy to make, while being secure and efficient to move the kind of current we are looking at.

We'll get to posting pictures as we get closer to assembly of the box, but what's a thread without photos? Here are a few of the sausage making shots we've been passing back and forth as we work.

Filippo

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fmorelli

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Alright ... my unit is completely assembled but not tested yet. I sent some parts out to @NoQuarter, as we've been collaborating on this project. Where I machined up some UHMWPE parts, I think Jim might take a stab and some drawings and 3D printing, since none of the pieces are particularly complex. I like this idea as it is far more repeatable for someone else. Let me post drawing updates. I'll post photos here now, and provide the link to the BMW Reprogramming Charger Google Presentation.

In the next post I'll provide a list of basic parts. Then I'll push up a variety of photos to get a sense of how it all comes together. Finally I want to put out some notes on lessons learned. This was way too much work, which comes with doing something bespoke with product packaging, the first time. I'm hoping Jim's 3D printing will help some of that, and I have a few other stubbed toes to share.

Filippo

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fmorelli

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Ok ... so photos. Let me first put up some connector photos. Unfortunately there are no connectors that can be purchased as standalones for a backplane - at least that @NoQuarter and I could find. So we had to make some. Probably many ways to skin this cat. I laid them out on copper with an awl, cut them with a bandsaw, fit, soldered, shaped.

c10.jpg c10b.jpg c11.jpg c12.jpg c13.jpg c14a.jpg c16.jpg c17.jpg

Jim made a really nice, compact connector to hold the variable trim resistor. I think he has a V2 in flight, with vertical access.

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Powerwerx connectors were used for cabling out to the car. These are high quality, USA made connectors.

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I have a ton of photos, just trying to cull a few to give people an idea.

Filippo
 

fmorelli

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Here's the chassis mount. Basically aluminum C channel, which I cut and brazed. It screws into the side holes on the PSU, giving the unit air over top and underneath. The chassis is drilled out to hold the 3 40mm fans. Typically Forstner bits are not used on aluminum, but this was soft stuff and I had no concerns. The chassis then sits on UHMWPE spacers, off the bottom. The whole thing is screwed down from the bottom.

Filippo

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ajm8127

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Wow, lots to like in this thread. That is a great solution for high power. I use a lower power supply capable of 30 amps. I've only seen it draw 30 amps once and that was when the battery was down a bit and then I turned the ignition on. The power supply was set to 13.8 volts and dipped slightly to 13.5 or so as the supply limited at 30 amps. If I hadn't been charging the battery and running the car at 13.8 volts simultaneously, I doubt that would have happened.


If I have had the supply float charging the car for a while and then I turn the ignition on, it draws about 10-15 amps. With 80 amps, you will never have a problem.

One thing I would not try is starting the car with the power supply attached, but that's what your circuit breaker is for.
 

fmorelli

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Well I did program a Samsonite suitcase to talk to a certain satellite, once. But I think that's off topic ...

Filippo
 

fmorelli

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Well it's not operating yet :) ... Jim is working on his, and once it is assembled, we'll determine and tandem a test regime.

Filippo