Cor
Posts: 154
Joined: Sun Jun 30, 2013 6:53 am
Delivery Date: 07 Jul 2015

Re: Anybody with 2011 or 2012 interested in upgrade to new battery?

Fri Feb 17, 2017 6:03 pm

Kris1 wrote:Also interested to hear your thoughts on swapping the new double thickness ( https://www.dropbox.com/s/qt88me809t3w5w2/1.25kwh.jpg?dl=0) modules into a G1 battery case.

Hi Kris,
Aha! so that is how the new 30kWh modules look like!
They appear to be a drop-in replacement for a pair of 24kWh modules, so I see no issues - I presume that they kept the order of the module interconnects the same, so I suspect that it is simply a matter of stripping the 3 sub-packs from the 30kWh battery of all their wiring and bus bars, fit the 2011/2012 bus bars and monitoring harness on the sub-packs, then first *measure* the voltages produced by the sub-packs to be indeed 90, 90 and 180Volts or higher *and* preferably measure the voltage on all BMS connectors to follow the correct cell numbering scheme as in the 2011/2012. Then mount the 30kWh modules into the G1 shell and attach all interconnecting bus bars (the critical one being the jumper between the two front quarter-packs!!!) before you plug the BMS in. By that time you should have 180V or higher between each of the inside connections to the black contactor box and the service disconnect and once the service disconnect is in, you should have 360V or more.
It seems doable to me and mechanics should work if thickness is indeed 2 2/3" as I expect (two old modules stacked together)!
Hope this helps,
Cor.

Kris1
Posts: 47
Joined: Fri Feb 28, 2014 10:38 pm
Delivery Date: 30 Sep 2013
Leaf Number: 200165
Location: Sydney Australia

Re: Anybody with 2011 or 2012 interested in upgrade to new battery?

Sat Feb 18, 2017 7:50 pm

Sounds achievable. Can your buyers access the 30kwh packs? If so what sort of $$ for one?

Cor
Posts: 154
Joined: Sun Jun 30, 2013 6:53 am
Delivery Date: 07 Jul 2015

Re: Anybody with 2011 or 2012 interested in upgrade to new battery?

Tue Feb 21, 2017 2:09 am

Cor wrote:Today I heard that finally a new 2015 Leaf with very low mileage arrived at the Dismantler, so I will go there Monday to pick up the battery and remove the modules in preparation of the swap next month.

OK, another update: today I drove (in the downpour) almost 300 miles (round trip) to pick up the battery.
First thing the dismantler said when he recognised me: "did you get my email?"
me: "Huh? When did you send it?"
him: "This morning, after I came it."
me (confused): "No, what is going on?"
him: "The battery is sold. We hired a new guy and while I was away last Saturday, he sold your battery.
We had taken the battery already out of the car so everything was ready for your pickup today (Monday)
but when I came in this morning, I noticed it gone, so I checked and it is sold and picked up already..."

I wanted to curse, since I had just struggled 3 hours through torrential downpour in a borrowed pickup truck to go there
and now the whole purpose of going there disappeared before my eyes.
The manager was very apologetic because he knows that I have been waiting a long time and he promised to do everything he could to see if he can get another car soon so he can offer me another battery....
Well, this was quite the plot-twist and so I had an even less pleasant 3 hours back through the rain...
To be continued!

Cor
Posts: 154
Joined: Sun Jun 30, 2013 6:53 am
Delivery Date: 07 Jul 2015

Re: Anybody with 2011 or 2012 interested in upgrade to new battery?

Tue Feb 21, 2017 3:32 pm

Kris1 wrote:Sounds achievable. Can your buyers access the 30kwh packs? If so what sort of $$ for one?

I will ask!

NiallDarwin
Posts: 19
Joined: Thu Jul 09, 2015 1:58 am
Delivery Date: 12 Dec 2015
Leaf Number: 004321
Location: New Zealand

Re: Anybody with 2011 or 2012 interested in upgrade to new battery?

Fri Feb 24, 2017 9:49 pm

Cor wrote:I have one BMS where *every* single one of the 24 ASICs that connect to groups of 4 cells (2 modules), has a crater in the plastic chip where the silicon spewed out in liquid form...
Cor.


Good work!

NiallDarwin
Posts: 19
Joined: Thu Jul 09, 2015 1:58 am
Delivery Date: 12 Dec 2015
Leaf Number: 004321
Location: New Zealand

Re: Anybody with 2011 or 2012 interested in upgrade to new battery?

Fri Feb 24, 2017 9:54 pm

Cor wrote:him: "The battery is sold. We hired a new guy and while I was away last Saturday, he sold your battery.


Ouch! Sorry to hear it.

NiallDarwin
Posts: 19
Joined: Thu Jul 09, 2015 1:58 am
Delivery Date: 12 Dec 2015
Leaf Number: 004321
Location: New Zealand

Re: Anybody with 2011 or 2012 interested in upgrade to new battery?

Fri Feb 24, 2017 9:56 pm

Kris1 wrote:Yeah, a replacement G1 BMS is what ND is after isn't it? Also interested to hear your thoughts on swapping the new double thickness ( https://www.dropbox.com/s/qt88me809t3w5w2/1.25kwh.jpg?dl=0) modules into a G1 battery case.

Thanks for the share. That looks made for short-circuiting. Be careful when you get one!

NiallDarwin
Posts: 19
Joined: Thu Jul 09, 2015 1:58 am
Delivery Date: 12 Dec 2015
Leaf Number: 004321
Location: New Zealand

Re: Anybody with 2011 or 2012 interested in upgrade to new battery?

Sun Feb 26, 2017 3:56 pm

So I got the replacement BMS in ok but some of the cells were pretty much dead-one at about 0.7V and one at about 1.6V! Here's what I did to fix them:
https://youtu.be/mBBk1ABKftg

After charging them as described above they came back to life and the car ran happily :D So I filmed a reverse spin-turn to celebrate:
https://youtu.be/slJOe7zzEd0

Unfortunately the low cells are not being brought into line by the BMS so I think they may be damaged. I am seeing a voltage difference of 100mV most of the time. Sometimes down to 60mV but when on full-power it can go up as far as 180mV. So I'm on the hunt for four good G2 modules in NZ to replace the bad ones.

I'm still planning a "how to swap batteries" video, basically summarising what I've done and pointing out the easy pitfalls to avoid!

Cor
Posts: 154
Joined: Sun Jun 30, 2013 6:53 am
Delivery Date: 07 Jul 2015

Re: Anybody with 2011 or 2012 interested in upgrade to new battery?

Mon Feb 27, 2017 12:50 am

NiallDarwin wrote:Unfortunately the low cells are not being brought into line by the BMS so I think they may be damaged. I am seeing a voltage difference of 100mV most of the time. Sometimes down to 60mV but when on full-power it can go up as far as 180mV. So I'm on the hunt for four good G2 modules in NZ to replace the bad ones.
It is well known that over-discharge will increase internal resistance of cells, so as long as they don't destroy themselves and come back they might have higher self-discharge and they typically sag deeper than other cells during high current discharge.
NOTE that cell 73 always reads lower during high current discharge, since it has the inter-pack connection voltage drop measured in with the cell voltage (the other pack connection is outside the measurement as it bridges the service disconnect and opto-coupler, so both sides of the interconnect are connected to the BMS, while cell 73 receives one measurement wire from one sub-pack and the other sense wire comes from the other sub-pack, so it measures both cell and the jumper between the two quarter-packs, adjacent to the contactor box.

Note also that the BMS only balances at 10mA of current, so if cells are out of balance or have higher self-discharge then the BMS will have difficulty getting them in line again.

DaveinOlyWA
Gold Member
Posts: 12073
Joined: Sat Apr 24, 2010 7:43 pm
Delivery Date: 10 Nov 2016
Leaf Number: 314199
Location: Olympia, WA
Contact: Website

Re: Anybody with 2011 or 2012 interested in upgrade to new battery?

Tue Feb 28, 2017 8:30 am

NiallDarwin wrote:So I got the replacement BMS in ok but some of the cells were pretty much dead-one at about 0.7V and one at about 1.6V! Here's what I did to fix them:
https://youtu.be/mBBk1ABKftg

After charging them as described above they came back to life and the car ran happily :D So I filmed a reverse spin-turn to celebrate:
https://youtu.be/slJOe7zzEd0

Unfortunately the low cells are not being brought into line by the BMS so I think they may be damaged. I am seeing a voltage difference of 100mV most of the time. Sometimes down to 60mV but when on full-power it can go up as far as 180mV. So I'm on the hunt for four good G2 modules in NZ to replace the bad ones.

I'm still planning a "how to swap batteries" video, basically summarising what I've done and pointing out the easy pitfalls to avoid!


hell with the batteries! wanna trade houses? :)
2011 SL; 44,598 miles. 2013 S; 44,840 miles.2016 S30 (build 10/2016)"low water marks" 24,261.3 miles.363 GIDAhr 80.66Hx95.95%kwh28.1QCs205,L2's 226
My Blog; http://daveinolywa.blogspot.com" onclick="window.open(this.href);return false;

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