Hallonpower X6-electromod User manual

18 June 2016

X6-ElectroMod

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

pg. 1

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.

Installation Manual

18 June 2016

X6-ElectroMod

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

pg. 2

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.

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

pg. 3

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.

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

18 June 2016

X6-ElectroMod

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

pg. 4

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.

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.

18 June 2016

X6-ElectroMod

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

pg. 5

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.

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).

18 June 2016

X6-ElectroMod

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

pg. 6

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.

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.

18 June 2016

X6-ElectroMod

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

pg. 7

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.

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.

18 June 2016

X6-ElectroMod

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

pg. 8

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.

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.

18 June 2016

X6-ElectroMod

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

pg. 9

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.

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

18 June 2016

X6-ElectroMod

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

pg. 10

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.