Here is a video of a 20 Cell 160 Amp hr Chevy Bolt Battery (Kit) for a 2001-2002 Gem Car
(Front battery tray) install. This was 2” 10 cell battery’s that we’re mounted together one on top of another & then linked together. New BMS Leeds were ran to JST plugs and then connected to a Chargery BMS 24 Balancer. They Battery is charged by a Chargery Battery Charger.
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I am posting here because Grant started the Thread and didn’t want to many open threads on this setup.
I purchased this Setup from @grantwest and working on tearing down my Gem right now. MY main question is the Zivan Charger. The two lines that come out of the Zivan Charger (green and red/black), I realize those lines probably tell the car whether the gem is charging or not. and if I disconnect the car will not move.
Since I am going to the Chargery Charger what do I do with those lines now? Grant thought I would connect them but he also wanted me to ask the Forum to find out.
see the pic for more details
Tyson is asking about the Zivan interlock wires.
What should he do with them He will Not be using the Zivan and he needed to know what should be done with the interlock wires. Examp
Should they be connected together
Yes connect them together
Thanks @Inwo
I will post pics here soon of my conversion. Grant saw I didn’t do my Dc to DC converter Recall so I called a dealer to get that done only 16 year later on that.
Tyson has the Old Circuit Board style DC/DC converter. His Dealer was nice enough to warranty his Old converter and Upgrade him to the New DC/DC Sure power converter. 2 steps forward 3 steps back LOL
2002 gem Ok I have the bolt battery all in the front and secure. I hooked up the b+ to the disco, the disco to the wire marked fuse post. I connected the b- to the shunt and the shunt to the b- on the controller. When I turn the disco on I get green zeros on the dash and they go away then nothing. I do get 84 volts to the controller and I did connect the old zivan interlock wires to a switch and switch it on and still no power or anything out of the controller.
Any help would be appropriated.
Can someone chime in and Offer some advice. I think Tyson’s problem revolve around, his removal of his Zivan Charger & the green and green and red interlock wires. I remember having the same issue with my 2002 long ago when I took out or switched around some interlock wires. The only person that was able to rescue me was My “Electronic “Lord and Savior David!
The bms is repaired.
No clue on the dead Gem. Interlock wires are bypassed.
Power to Pin 2 turns on display.
On the Interlock.
One wire I think it’s Green (gets 72 volts)
Not sure if the other gets ground. I think Tyson said he tired both of these wires together???
So can someone explain how the interlock (electronically) on a Zivan works.
Example: I was thinking the charger has a switch and anytime the switch is energized with 110 power it Opens up and breaks the connection of the 2 wires and that makes it so your car doesn’t run. Like I said it’s fuzzy how it’s supposed to work his car ran and worked fine b4 he took out the delta q
Yes, that’s how all the interlocks work.
However the older cars break the line to the key switch. I can’t find a schematic for Zivan.
I believe the internal relay contacts break the 12v line.
So the two interlock wires are 12v in and 12v out.
That makes sense, perhaps someone will come up with a wire diagram
Check for battery ground 72v B- at terminal #6 of pwb.
Red meter to B+, blk meter to #6. read dc volts 0-200 scale.
Should read battery voltage if interlock bypassed and key is on.
Diagram from @JarJarJava
I put the Zivan charger back in and connected it up like it was when it worked.
ok from Controller B- to #6 I get reading starting from 1.0 and then it slowly goes down to .08
if I put it from B+ to #6 I get readings starting from 1.0 then it slowly goes down to down to .09
that was all read with the key on
That tells me it’s floating. ie. nothing connected to it.
Connect interlock wires to B-. Both if you don’t know which is which.
If #6 doesn’t read 72v when measured from B+, a wire is disconnected some place.
Connecting #6 to B- will bypass the key and hotwire car.
Connecting the key to B- will bypass the interlock only.
afaik from schematic.
OK I figured out what was wrong. I finally got it to work! This whole time I had the Main NEG on the wrong NEG Battery Terminal. So I only had half the pack hooked up to the GEM. After moving the NEG over to the right NEG terminal on the Second pack it fired right up.
on a 2002 I did figure out that if you take the interlock (RED/GREEN) wire and put it on a two prong switch with the Green Wire that goes in the Zivan it works just fine. you can use the switch as a extra lock out (sorry kids, I have a hidden switch now)
I will update the forum as soon , I am trying to get this all cleaned up now.
Thanks for everything from Everyone. Especially @grantwest and @Inwo for being patient with me.
