Hallonpower X6-electromod User manual

18 June 2016

X6-ElectroMod

A 160AH 1.5KW Electrical Power Generator for the BMW X6

pg. 1

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may be modified at any time and without notice.

Installation Manual

18 June 2016

X6-ElectroMod

A 160AH 1.5KW Electrical Power Generator for the BMW X6

pg. 2

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implied that any item sold here, is a product authorized by or in any way connected with any vehicle manufacturers displayed on this page. This document

may be modified at any time and without notice.

Contents

System Installation..................................................................................................................................4

Prerequisites .......................................................................................................................................4

Fitting the System Panel into an BMW X6 E71 ...................................................................................5

Battery base leveling.......................................................................................................................6

System Panel Fastening onto the car body.....................................................................................6

Power Distribution Vertical Panel...................................................................................................7

Important Cable Considerations before Installation ..........................................................................8

M300 Charger cable modifications .................................................................................................8

Familiarization with the System............................................................................................................10

Side view ...........................................................................................................................................10

Top-down View .................................................................................................................................10

1. The Power Management Area ......................................................................................................11

Thermal Sensors............................................................................................................................12

2. The Service Battery Bank Compartment.......................................................................................12

Battery Fastening ..........................................................................................................................12

3. The Power Distribution Area.........................................................................................................13

4. The Inverter Area ..........................................................................................................................15

5. The System Control Panel (SCP)....................................................................................................18

SCP Baseplate................................................................................................................................18

Input & Output connectors of the SCP baseplate.........................................................................18

System Cable Harness ...................................................................................................................19

Notes & warnings..........................................................................................................................20

Installation procedure.......................................................................................................................21

A. System Panel (SP) .....................................................................................................................21

B. Inverter .....................................................................................................................................21

C. Cable Harness............................................................................................................................22

D. Chassis GND..............................................................................................................................22

E. Power Distribution Vertical Panel ............................................................................................. 22

F. Power Distribution Bottom Panel .............................................................................................23

G. Power Distribution Top Panel & CBs ........................................................................................24

H. The Batteries.............................................................................................................................25

I. System Control Panel (SCP)........................................................................................................26

18 June 2016

X6-ElectroMod

A 160AH 1.5KW Electrical Power Generator for the BMW X6

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may be modified at any time and without notice.

Powering ON & Systems Check......................................................................................................... 27

APPENDIX A...........................................................................................................................................31

Cables & Connections .......................................................................................................................31

System Cable Harness Details (see also Table of Connections 22-39)............................................. 32

Table of Connections ........................................................................................................................33

Connections by Type.........................................................................................................................35

Cable List ...........................................................................................................................................39

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X6-ElectroMod

A 160AH 1.5KW Electrical Power Generator for the BMW X6

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implied that any item sold here, is a product authorized by or in any way connected with any vehicle manufacturers displayed on this page. This document

may be modified at any time and without notice.

System Installation

Prerequisites

A. Prepare the car:

Before fitting the System Panel in the car,

1. The Luggage Compartment Pan (A) (part no. 51476981061) and the Battery Cover (B) (part

no. 51476981050) will have to be removed to make room for the installation.

2. The X6 Interior-Rear-Storage Compartment Right (C) (part no. 51476981048) sits right

underneath the Right Flap (D). An 8cm hole will need to be opened on the front side of this

Storage Compartment, large enough for the connecting Powerpole plugs to pass through it.

B. Prepare the PM panel (see The Power Management Area):

The Power Management Panel houses 3 components from CTEK and a Grounding Bus Bar (GBB).

CTEK M300 charger #1.

CTEK Smartpass #2.

CTEK D250S Dual #3.

Grounding Bus Bar #8 (GBB).

1. Attach all the PM components (D250S, Smartpass, M300 and Grounding Bus Bar).

2. Now connect all cables to each PM component (LOOM1 & LOOM2) (see Appendix A).

D. Prepare the SP by making sure:

1. All 3 base brackets are attached and

2. Both side brackets are not attached so as not to interfere with the installation (we will add

them later on).

3. The 2 bottom Inverter screws are screwed onto the SP to allow easy Inverter fastening.

4. Attach the PM panel to the SP and

5. Take the SP & the 3 other panels to the car for installation (see Installation procedure).

CAUTION: Please arrange for adequate protection of your rear bumper during installation to protect

it from scratches.

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A 160AH 1.5KW Electrical Power Generator for the BMW X6

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Fitting the System Panel into an BMW X6 E71

The solution is housed on a single plywood panel that fits snugly and discretely underneath the

trunk floor in the luggage compartment of your BMW X6 (also called the Trunk Floor

Compartment).

Before fitting the System Panel, the Luggage Compartment Pan (A) (part no. 51476981061) and

the Battery Cover (B) (part no. 51476981050) will have to be removed to make room for the

installation. These parts are found

under the trunk floor. Place these

items in storage as they will no

longer be needed.

A System Control Panel (SCP) is also included in the solution which is housed on the right hand

side of the trunk of the BMW X6, also discretely and seamlessly blended into the Right Flap (D)

found in the trunk.

The X6 Interior-Rear-Storage

Compartment Right (C) (part no.

51476981048) sits right underneath

the Right Flap (D). All wiring from the

Trunk Floor Luggage Compartment,

where the solution is installed, will

have to pass through this Storage

Compartment (C) in order to connect

to the SCP (see section about the

System Control Panel).

For this reason a hole will need to be

opened on the front side of the

Storage Compartment (C), large

enough (about 8cm) for the connecting Powerpole plugs to pass through (the hole will be out of

sight, hidden below the trunk floor level and completely covered by the SCP which will be sitting

over it).

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A 160AH 1.5KW Electrical Power Generator for the BMW X6

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may be modified at any time and without notice.

Battery base leveling

After removing the Battery Cover (B)

from the luggage compartment below

the trunk floor of the X6, you will notice

that the floor is quite uneven.

For this reason a suitable floor leveling

material will be required in order for the

batteries to sit level.

You could try using several small pieces

of fitted carpeting, layered on top of

each other to fill in the gaps and grooves. Finally, once you have established a level base, you can

top it off with a single larger piece of carpeting to form the base where the batteries will sit.

Do not make this base too thick otherwise you may have trouble closing the trunk

floor after you install the batteries.

System Panel Fastening onto the car body

The System Panel is attached to the base of the trunk of the X6 by 3 L-shaped brackets that slot into

existing floor grooves.

These are not meant to fasten the panel in position with screws but are rather meant to restrict its

movements both vertically and horizontally, keeping it aligned and steady.

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X6-ElectroMod

A 160AH 1.5KW Electrical Power Generator for the BMW X6

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may be modified at any time and without notice.

Two side brackets are actually screwed onto the sides of the trunk. These are actually what really

hold the System Panel in position. So once you lower the panel into the luggage compartment, slide

the 3 bottom brackets all the way into the floor slots.

Wait until the Power Distribution Vertical Panel has been placed into position and then using two

screws, fasten these side brackets onto the sides of the trunk.

Power Distribution Vertical Panel

This panel separates the Power Distribution area from the Service Battery Bank compartment. It is

used to fasten the PD area components and helps

to keep the batteries in place.

It will require a screw to hold it in position against

the rear wall of the trunk floor compartment.

Please follow the detailed installation instructions

in the ‘Installation procedure’ section.

There are a total of 3 screws that will ever be drilled into any part of the car in this

solution. We tried to keep any invasive means to an absolute minimum. This is why

we have employed the L-shaped brackets to provide us with the necessary stability

without using any screws, which also makes removing the panel a breeze.

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X6-ElectroMod

A 160AH 1.5KW Electrical Power Generator for the BMW X6

pg. 8

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implied that any item sold here, is a product authorized by or in any way connected with any vehicle manufacturers displayed on this page. This document

may be modified at any time and without notice.

Important Cable Considerations before Installation

M300 Charger cable modifications

Both the AC cable of the charger and the DC out cables have to be modified to connect to the rest of

the system.

1. The M300 AC cable must have a

plug change. Allow enough cable

to be able to reach the SCP.

Remove the mains plug from the

cable and replace it with a C14

plug as shown. This will be able to

connect to the bottom of the SCP

and receive AC current from

there.

2. The M300 DC Out cable needs to

also have its plug changed (not

shown here). Allow enough

cable to be able to reach the

SCP. Remove the DC plug from

the cable and replace it with 2x

Anderson Powerpoles. Make

sure the positive red cable is

fitted with a red Powerpole and

the negative black cable is fitted

with a black Powerpole. These will be able to connect to the colour matching Powerpoles on a

long cable coming out of LOOM 2 (shown above).

When connecting the M300 Powerpoles to the LOOM2 matching Powerpoles,

zip-tie them together so that they do not get disconnected during installation.

If you find that the M300 is not charging your batteries, it is probably because these

connectors were disconnected. To avoid the inconvenience of removing cables and

batteries to get to this joint, make sure you tie them up pretty well!

WARNING!

Connect the M300 only to LOOM2 colour matching Powerpoles (red&black)!

Do not connect to loom1 Powerpoles (white&black) which are designed to output DC

current. Connecting here may damage your charger.

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A 160AH 1.5KW Electrical Power Generator for the BMW X6

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may be modified at any time and without notice.

3. The D250/AB-M300/P cable (shown in yellow) has to be soldered directly onto the DC +ve

output cable of the M300 charger (shown red), at the point where it passes right below the

D250S module. The M300 +ve cable must not be severed here.

Instead it must just be striped locally to allow the soldering of the 2 cables to take place. Please

insulate the joint properly.

The rest of the cable is allowed to continue until it attaches to the System Control Panel via the 2

Anderson Powerpoles mentioned above.

The rest of cabling should be done in accordance with Appendix A and specifically with the

help of ‘Table of Connections’ or ‘Connections by Type’.

Do not be intimidated by the long listings. There are actually only 21 single cables that must

be connected and another 10 connections involving the SCP baseplate and the LOOMs.

You will find particularly useful the ‘Connections by Type’ table, since it lists each module and

every connection going to it.

The next section will walk you through the whole process

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A 160AH 1.5KW Electrical Power Generator for the BMW X6

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All manufacturer names, symbols, and descriptions, used in our images and text are used solely for identification purposes only. It is neither inferred nor

implied that any item sold here, is a product authorized by or in any way connected with any vehicle manufacturers displayed on this page. This document

may be modified at any time and without notice.

Familiarization with the System

The solution is split into 6 main sections.

1. The Power Management Area that houses the Power Management Panel.

2. The Service Battery Bank Compartment.

3. The Power Distribution Area.

4. The Inverter Area (on the rear of the System Panel - not shown above).

5. The System Control Panel (SCP) (not shown below).

6. The Cable Management Area (for wiring see Appendix A).

Side view

Top-down View

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A 160AH 1.5KW Electrical Power Generator for the BMW X6

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may be modified at any time and without notice.

1. The Power Management Area

The Power Management Panel houses 3 components from CTEK and a Grounding Bus Bar (GBB).

1. CTEK M300 charger #1.

2. CTEK Smartpass #2.

3. CTEK D250S Dual #3.

4. Grounding Bus Bar #8 (GBB).

Each component has to be screwed into place on the Power Management Area Panel.

Once this is done, the Power Management Area Panel in turn should be taken and fastened onto the

front of the System Panel using the four

fastening holes provided on the System Panel.

All wires should be fastened securely and

threaded to their relevant destination

according to the wiring diagram (see wiring

section). When finished, it should look

something like this.

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A 160AH 1.5KW Electrical Power Generator for the BMW X6

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may be modified at any time and without notice.

Thermal Sensors

The M300, Smartpass and D250S each come with a thermal sensor cable (#10) attached to the

device. These should be attached on the top surface of one of the batteries in the Service Battery

Bank, preferably near the positive pole.

2. The Service Battery Bank Compartment

The area houses the Service Battery Bank.

If choosing your own batteries, please make sure the model you choose will be smaller than the

space specified below. Between 1 or 2 large capacity batteries can fit in this space, depending on

their dimensions and protrusions.

WARNING!

Both batteries must fit in this space: Length 11.13in (283mm) x Width 13.2in (336mm) x

Height 9.25in (235mm). Not even a millimetre larger! You may have to remove the battery

holding straps after inserting the batteries into the Service Battery Bank compartment.

Store these in a safe place for when you will need to replace the batteries or in case you

may need to service the system.

Battery Fastening

On the left side of the Service Battery Bank, we have the main Alternator Battery and on the right

side, the Power Distribution Vertical Panel holding the batteries from moving in either direction. If

required, a battery fastener can be used to hold the batteries down onto the trunk floor. In our case

we found that this is not necessary.

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A 160AH 1.5KW Electrical Power Generator for the BMW X6

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may be modified at any time and without notice.

3. The Power Distribution Area

This hosts 4 CBs and a motorized switch (BEP 701MD).

The BEP 701-MD’s main functionality is to provide a ‘Parallel Battery Mode’ for the system.

WARNING!

For normal system operation, make sure that Parallel Mode is OFF.

Engage Parallel Mode only in emergencies,

when the Alternator Battery cannot start the engine.

The BEP 701-MD’s secondary functionality is to of course distribute power to the system, via the

CBs. As we have already seen, the switch is connected directly to each battery bank.

From here various cables connect to CB#4, CB#5 and CB#7 which are responsible for protecting,

switching and distributing power over those lines.

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A 160AH 1.5KW Electrical Power Generator for the BMW X6

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may be modified at any time and without notice.

All power flowing to each part of the system passes through this switch,

up to 275A continuous (see ‘Wiring’ section for more information).

CB#4&#5 feed the Smartpass with power from each battery bank. CB#4

feeds power from the Alternator Battery, while CB#5 feeds power from

the Service Battery Bank (see ‘Wiring’ section for details). The power

cables feeding these CBs come from the BEP-701MD switch directly,

which is capable of either delivering the power separate or after bridging

the battery banks (parallel mode).

CB#4&#5, rated at 150A, protect the D250S & Smartpass according to

the manufacturer’s guidelines, instead of a 150A fuse, meanwhile

providing a way for the user to easily switch these modules ON or OFF.

CB#6, rated at 50A, is used to protect the Non-Critical Consumers 12V DC

output of the Smartpass as well as providing a way for the user to easily

switch this output ON or OFF.

Finally CB#7, rated at 200A, is responsible for feeding power into the

SINERGEX Puresine2 1500W Inverter, while at the same time protecting the

unit according to the manufacturer’s guidelines, in place of a 200A fuse.

CB#7 also provides a convenient way to switch the inverter ON and OFF

without having to fiddle around to find its 3-way switch behind the System

Panel. It is recommended to place this switch in the II position at

installation, which places the inverter in remote control mode. Thus when

CB#7 is also switched to the ON position, the inverter can easily be turned ON or OFF directly from

the SCP.

It is recommended to place CB#7 to the OFF position when you no longer require

use of the inverter to avoid anybody turning it on or even leaving it on accidentally.

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A 160AH 1.5KW Electrical Power Generator for the BMW X6

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4. The Inverter Area

The System Panel also houses a Power Inverter, installed on its rear side, for the generation of 240V

AC power on the go.

WARNING!

Whatever inverter you may choose, the most important consideration is its width which

must be less than 22cm otherwise it will not fit on the back of the System Panel. Its length

and height can be anything you want.

WARNING!

The second most important consideration is that its continuous power output does not

exceed 3000W. The system is designed to handle continuous currents of up to 275A (limited

only by the bridging switch) to any Inverter and therefore a 3KW device would be the limit.

The other important consideration is the remote control unit. This has to be able to

fit in the slot on the System Control Panel. The slot has a hole of 96mm x 86mm and

was designed for remote controls of 130mm x 120mm dimensions.

Of course any other remote can be fitted, but you would have to cut a custom size

hole on a 130mmx120mm aluminium cover which we can provide.

Every possible measure has been taken to ensure that the positioning of the inverter

follows the manufacturer’s guidelines. Placing the inverter on the reverse side of the

System Panel separates it from any contact with the batteries. Make sure you

adhere to these guidelines while in operation.

ON / OFF/ REMOTE (Main) switch:

a. Before installing the inverter, make sure the main switch must be “OFF”.

b. Before using the remote unit, make sure the main switch must be “REMOTE”.

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A 160AH 1.5KW Electrical Power Generator for the BMW X6

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Installation:

Where to install:

The power inverter should be installed in a location that meets the following requirements:

Dry –Do not allow water to drip or splash on the inverter.

Cool –Ambient air temperature should be between 0 and 40 , the cooler the better.

Safe –Do not install in a battery compartment or other areas where flammable fumes may

exist, such as fuel storage areas or engine compartments.

Ventilated –Allow at least one inch of clearance around the inverter for air flow. Ensure the

ventilation openings on the rear and front of the unit are not obstructed.

Dust –Do not install the Inverter in a dusty environments where are dust, wood particles or

other filings/shavings are present. This dust can be pulled into the unit when the cooling fan

is operating.

Avoid excessive cable lengths but do not install the Inverter in the same compartment as

batteries.

Use the recommended wire lengths and sizes (see section 3-5). Also do not mount the

Inverter where it will be exposed to the gases produced by the battery. These gases are very

corrosive and prolonged exposure also will damage the Inverter.

DC Input Terminals

Model

DC Input Voltage

12 V

Minimum

Maximum

10.5

WARNING!

Connect to 12V battery ONLY! (+) is positive, (-) is negative.

WARNING!

Reverse polarity connection will blow internal fuse and may damage inverter permanently.

WARNING! Shock Hazard.

Before proceeding further, carefully check that the Inverter is NOT connected to any

batteries, and that all wiring is disconnected from any electrical sources. Do not connect

the output terminals of the Inverter to an incoming AC source.

The X6-Electrmod bests the manufacturer recommendations for wiring and our

solution provides a 200A CB in place of the 200A fuse recommended.

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A 160AH 1.5KW Electrical Power Generator for the BMW X6

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Connect the cables to the power input terminals on the rear panel of the inverter.The red terminal is

positive (+) and black terminal is negative (-).

Insert the cables into the terminals and tighten screw

to clamp the wires securely.

WARNING!

Make sure all the DC connections are tight (torque to 9 –10 ft-lbs, 11.7 –13 Nm). Loose

connections could result overheat in a potential hazard.

Battery to inverter cable

connection

Do not place anything between battery cable lug and terminal surface. Assemble exactly as shown.

AC Safety Grounding:

The AC output ground wire should go to the grounding point for your loads

(for example, a distribution panel ground bus).

This is taken care of internally in the SCP.

What we have included here are some of the most important points regarding the

installation and operation of this inverter, making it relevant to this manual.

Please consult the Inverter user manual for more details and information.

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5. The System Control Panel (SCP)

The SCP is installed in the right trunk flap of the X6 and makes use of the

depression in the flap to house its various components.

SCP Baseplate

Input & Output connectors of the SCP baseplate

External View

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may be modified at any time and without notice.

System Cable Harness

The SCP is making use of Anderson Powerpole connectors for their ease of use, rigidity, flexibility

and high current capability of 30A or 45A.

The cable harness comprises of 3 plugs and terminates onto the baseplate of the SCP.

1. Anderson Powepole 8x pole plug (LOOM1).

2. Anderson Powepole 4x pole plug (LOOM2).

3. C14 male plug (M300 AC plug replacement).

Cable Loom #1

Cable Loom #2

Cable Loom for the Powerpole#1 socket on the

System Control Panel...

Cable Loom for the Powerpole#2 socket on

the System Control Panel...

Additionally you should have the following:

1. Cable with 3 wires onto 1x WAGO plug (coming out of LOOM1)

2. Cable with 2 wires onto 2x Powerpoles (white&black)

(out of LOOM1 - DC Out for internal devices)

3. Cable with 2 wires onto 2x Powerpoles (red&black)

(out of LOOM2 –connects to DC Out of M300 charger)

The M300 charger has to have its DC output plugs replaced with 2x Anderson

Powerpoles in order to connect to LOOM2 (#1 & #2 on baseplate).

The 3 wires on LOOM1 (#4 red/green/black on baseplate) are coming from the

BEP 701-MD switch and connect to LOOM1 with a WAGO plug.

The -ve ground cable on LOOM2 (#3 on baseplate,#6 right) is taking up 2

Powerpole slots.

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Notes & warnings

1. 12V DC OUT (#7) can sustain 80A from the CTEK SMARTPASS module. However this output is

limited to 50A continuous (and 100A intermittent) by the LCD Power Meters/Analyzers and

further limited down to a rating of 15A (even with the engine off) by each of the 2 DC out

receptacles on the SCP faceplate.

Therefore the maximum amp rating for this line should be 2x15A=30A max, for a maximum

power rating of 12x30A=360W continuous for both outputs (180W max each).

WARNING!

Do NOT connect devices exceeding 180W on any of the 2 DC receptacles.

This will probably damage the receptacles. If you require additional DC power, you can use

the interior Anderson plugs (see below).

2. DC OUT metered (#6) is essentially another DC socket in Anderson connector format, in

addition to the 2 already found on the face of the SCP.

This allows easy and continuous access (even with the engine off) to DC power from

anywhere inside the luggage compartment underneath the trunk floor of your car (such as

LED lights to light up the luggage compartment).

Anderson plugs have a 45A rating therefore the 12V DC OUT line is protected by a 50A CB

(CB#6) for a maximum output of 600W.

3. 12V SOLAR IN (#5) is limited to 50A continuous by the LCD Power Meters/Analyzers and to a

maximum of 23V and/or 300W by the CTEK D250S. The CTEK D250S can protect itself from

over current situations, but its manual warns about the solar panel voltage.

WARNING!

Do NOT connect 2 panels in series.

Do not exceed 23V input. Do not exceed 300W input.

4. AC Input (#10) is powering the CTEK M300 300W AC charger. This input is protected with a

10A 240V fuse in the UK plug on the charging cable that connects to the SCP faceplate.

The ‘AC Charging’ Digital LCD Power Meter/Analyzer is metering the charger’s DC

output (#1) into the battery bank and not its own AC input.

5. AC OUT (#11) is using the SINERGEX Puresine2 1500W Inverter. The Inverter is quite capable

of dealing with all extreme scenarios. Even so, this output is protected with a 10A 240V fuse

in the UK plug on the cable that connects to the inverter. Equipment drawing in excess of

10A@240V AC are not recommended as they will be stressing the Inverter and the system in

general and subsequently blowing this fuse.

Table of contents

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