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Old 01-26-2019, 10:12 AM   #1
MCJEFE
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Default DIY 101 - 14 cell Nissan Leaf lithium pack

Ok, there are a bunch of great build threads on here for the Leaf cells and I am pretty sure that I have read them all several times over and I am thankful for the information and help the folks on BGW provide daily to us backyard knuckle bangers.

I just finished up the last details from building my first pack last night and while I am happy with it there are things I will do differently this time and I did not go into a lot of detail on my last build thread... I realized that I have a unique opportunity to actually to learn on one build and then document a second build once I had a clue what I was doing. So I figured that while I still have the wide eye deer in the headlights look and still remember what I didn't know I would try and organize my newly found skills and knowledge.

The basic system:
- 14 cell, 120 ah. (~ 40 mile range?) - $2,050.
- Zeva 8-16 Cell BMS, VM3 monitor and CAN bus current sensor, temp sensor and Gigavac 240 contactor (for both HV and LV disconnect) - $525
- 58.4v, 10 amp charger (out of stock so this may change...) - $90

There are many ways to get this project done and I welcome input and lessons learned from others that have built packs.

My first pack is in a '05 CC Precedent this pack is going into a '16 EZGO RXV. But it really doesn't matter anymore than it matters what you put a AA battery into.

Sourcing the big parts:
I started with two 14 cell sets from the EV Battery Center out of a 2017 Nissan Leaf. Neli does not keep the website updated with current inventory, call her to see what she has. The modules are also available on Ebay there are a number of recent threads on sourcing modules. EV did not have the DIY kits or DIY end plates in stock, I was getting ready to fabricate my own when I got two sets from Pingeye3. I did ask EV to include the OEM end plates in case I needed a plan B for mounting as well as the original BMS tap connectors.





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Old 01-26-2019, 10:31 AM   #2
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Default Re: DIY 101 - 14 cell Nissan Leaf lithium pack

I am building this basic system but with the 600 amp CAN bus current sensor instead of the current shunt and I will add a sleep switch.

Pingeye3 provided me with a CAD wiring diagram for the first pack I did. We have since changed from using two disconnect relays to using just the single Gigavac 240 contactor and moved a wire to allow the system to be reset easier. The BMS HV relay and LV relay connections are wired in series using the Gigavac to isolate the battery pack in the event of either high or low voltage condition. I will post the wiring diagram after I have made the corrections. More on this later...

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Old 02-11-2019, 08:38 AM   #3
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Default Re: DIY 101 - 14 cell Nissan Leaf lithium pack

Excellent work on this build, as well as this detailed thread! I have been able to better understand the wiring and such through this thread! THANK YOU!

You mentioned in post #2
Quote:
Originally Posted by MCJEFE View Post
I am building this basic system but with the 600 amp CAN bus current sensor instead of the current shunt and I will add a sleep switch.
I am curious why you went with the Hall Effect current sensor, rather than just the current shunt? What advantage does the Hall Effect current sensor give you, over just the current shunt?

If I understand correctly the Hall Effect current sensor is really only needed in "high" current systems. Which from what I have seen on this forum, our 48v systems, even with the "max 58.4v" Nissan Leaf battery packs, are not considered to be. Think I remember seeing posted lower than 500 amps being the highest seen. In regards to our applications here, I suppose this begs the question: What is considered to be high current?
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Old 02-14-2019, 01:56 PM   #4
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Default Re: DIY 101 - 14 cell Nissan Leaf lithium pack

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Originally Posted by BBBHC View Post
Excellent work on this build, as well as this detailed thread! I have been able to better understand the wiring and such through this thread! THANK YOU!



You mentioned in post #2 I am curious why you went with the Hall Effect current sensor, rather than just the current shunt? What advantage does the Hall Effect current sensor give you, over just the current shunt?



If I understand correctly the Hall Effect current sensor is really only needed in "high" current systems. Which from what I have seen on this forum, our 48v systems, even with the "max 58.4v" Nissan Leaf battery packs, are not considered to be. Think I remember seeing posted lower than 500 amps being the highest seen. In regards to our applications here, I suppose this begs the question: What is considered to be high current?
So far the maximum current that I have seen in the Precedent was a surge of around only 270 amps (XCT 500, 500 amp solenoid, 2 ga cable and OEM motor). So my decision to use the Hall current sensor vice the shunt and the Gigavac as a single HV/LV disconnect (wired in series) was based primarily on keeping the wiring circuits as simple as I could, CAN Bus, while maintaining HV/LV protection. There's a lot of people on here much smarter than I and Sergio's relay ladder is a great design and I admire his engineering on BGW but he won't be there with me if a component craps out and I'm trying to sort it out in a parking lot... which is why I chose to K.I.S.S (keep it simple) my wiring.

There's no end of ways to get it done.

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Old 02-14-2019, 02:14 PM   #5
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Default Re: DIY 101 - 14 cell Nissan Leaf lithium pack

MCJEFE, by no means I am trying to convince anyone, but no one should be concerned because they think is complex, I on purpose drew that last diagram not to be 'invasive'.

All that system does is complete the "sleep" signal to negative, so if everything were to fail, all someone needs to do is flip the 'charge/sleep' switch or simply pull any of the 1/4" quick connect from the relay contacts and the circuit no longer has any affect on the system.

Also to clarify shunt, Zeva only supports a maximum of 500 Amps for a hardwired shunt so if You cart needs to read more than 500 Amps, the only solution is a CAN version (which can be a resistor or a Hall effect).

If your cart uses less than 500 Amps, the smaller shunts provides better resolution than the bigger ones.

Can't wait for my Lead Acid batteries to die
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Old 02-14-2019, 06:17 PM   #6
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Default Re: DIY 101 - 14 cell Nissan Leaf lithium pack

To follow up on what Sergio said about the shunts; I use a 200 amp shunt and it's been fine with momentary spikes of around 400amps. IIRC it can take a max of 500amps for 10 seconds, so it should suffice for our needs.
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Old 02-14-2019, 06:47 PM   #7
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Default Re: DIY 101 - 14 cell Nissan Leaf lithium pack

Quote:
Originally Posted by Sergio View Post
MCJEFE, by no means I am trying to convince anyone, but no one should be concerned because they think is complex, I on purpose drew that last diagram not to be 'invasive'.

All that system does is complete the "sleep" signal to negative, so if everything were to fail, all someone needs to do is flip the 'charge/sleep' switch or simply pull any of the 1/4" quick connect from the relay contacts and the circuit no longer has any affect on the system.

Also to clarify shunt, Zeva only supports a maximum of 500 Amps for a hardwired shunt so if You cart needs to read more than 500 Amps, the only solution is a CAN version (which can be a resistor or a Hall effect).

If your cart uses less than 500 Amps, the smaller shunts provides better resolution than the bigger ones.

Can't wait for my Lead Acid batteries to die [emoji38]
If you ahem... happened to "forget" to water your batteries I'm pretty sure they will wither and die an early death like my wife's herb garden... just a thought (might want to source the new batteries first!).

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Old 01-26-2019, 10:47 AM   #8
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Default Re: DIY 101 - 14 cell Nissan Leaf lithium pack

I'll be following this. Your other build was high quality! I've been hoping someone would do a very detailed build thread of this system!
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Old 01-26-2019, 11:30 AM   #9
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Default Re: DIY 101 - 14 cell Nissan Leaf lithium pack

Nice job, your first build was very clean and fun to watch. Looking forward to the next.
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Old 01-26-2019, 11:46 AM   #10
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Default Re: DIY 101 - 14 cell Nissan Leaf lithium pack

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Originally Posted by izzybird View Post
Nice job, your first build was very clean and fun to watch. Looking forward to the next.
This is the RXV I got this week that this pack will eventually go into and it's currently down at Pingeye3's place... He got board and pulled the old batteries. Since the batteries were out he used the opportunity to make some templates for the battery box... Those ended up made into aluminum and installed... With the old batteries out the electric brake sets. So he grabbed a pack he had on the bench and problem was solved... not so sure how well my clubs are going to fit. Good to have friends like this!

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