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.
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,