Atkam
Posts: 5
Joined: Fri Jan 16, 2015 3:33 am
Delivery Date: 16 Feb 2015

Re: Extra Battery, How to Integrate with 24kWh Traction Battery?

Tue Sep 27, 2016 6:54 am

collink wrote:I've done it successfully. I added 12kwh worth of batteries in the "trunk" area of a 2012 Leaf. It has been driven around for months thereafter. I can't say that there are never any problems but they're rare and clear with a power cycle. The car used to get perhaps 55 miles per charge but now I can just barely squeeze out 85 miles if I really run it dead. However, my integration was a bit more involved than the average hobbyist project. The Leaf BMS is smart enough to do many checks before it'll enable anything and that makes it tough.

1. I'm connected in line with the big power wires coming out of the main pack.
2. I have my own contactor to trigger my pack in
3. I've tapped the power wires going to the main pack's contactors so I know when they're closed
4. I'm reading CANbus from both the Leaf BMS and a BMS on the add-on 12kw pack
5. You have to close your contactor only once the main system has precharged and closed for driving.
6. You must open your contactor immediately if the main pack opens
7. You can't close until the voltages measured on both sides are almost the same. Sometimes this delays linking the packs until driving for a while or charging for a while.

Basically, it is computer controlled and uses a contactor. If you don't cooperate that way then the BMS will scream at you and you go nowhere. I wouldn't say that such a project is super easy but I can vouch for it being possible. You absolutely cannot have voltage from your pack getting to the motor controller or other HV components until the Leaf is ready. Otherwise, the car will slap you and it'll be hard to clear the errors. My system is fully automatic now but it took a lot of work and experimentation to get there.




Hi

Thank you very much "Collink" for very important basic input because confirm my principle how to plan to do it.
Is observing status of main pack contractor + voltage primary and secondary battery pack enough for connect battery together or you on your case check additional conditions (form CAN bus....) ?

Which BMS are you use?

Is second battery requires the BMS configured in way that never reaches more than 4,1V per cell with strong balance current.

best regards
ATKAM

User avatar
TonyWilliams
Posts: 10024
Joined: Sat Feb 19, 2011 1:48 am
Location: San Diego
Contact: Website

Re: Extra Battery, How to Integrate with 24kWh Traction Battery?

Tue Sep 27, 2016 11:41 am

Great job. I hope many hobbyists can capitalize on your work.

Atkam
Posts: 5
Joined: Fri Jan 16, 2015 3:33 am
Delivery Date: 16 Feb 2015

Re: Extra Battery, How to Integrate with 24kWh Traction Battery?

Sat Sep 30, 2017 1:15 pm

Finally I finish with full integration my additional battery parallel with main battery. I expect additional 100-150 km. Testing is in progress. Please find below some sample picture.
thank you: turbo3, gerygid, leaf xpack, jehugarcia, Njah kavin, HBPowerwall, Damien Maguire, Wolf Tronix, mikeatyouttube and many others which gave me useful information for this hobby project.

br
ATKAM

https://drive.google.com/file/d/0BxKOh5 ... sp=sharing
https://drive.google.com/file/d/0BxKOh5 ... sp=sharing
https://drive.google.com/file/d/0BxKOh5 ... sp=sharing
https://drive.google.com/file/d/0BxKOh5 ... sp=sharing
https://drive.google.com/file/d/0BxKOh5 ... sp=sharing
https://drive.google.com/file/d/0BxKOh5 ... sp=sharing
https://drive.google.com/file/d/0BxKOh5 ... sp=sharing

acuzzone
Posts: 4
Joined: Sun Dec 04, 2016 1:12 pm
Delivery Date: 04 Dec 2016

Re: Extra Battery, How to Integrate with 24kWh Traction Battery?

Sun Oct 01, 2017 1:38 pm

Forgive my ignorance here: Does this additional battery charge the traction battery or does it directly power the motor?

User avatar
davewill
Posts: 4793
Joined: Thu Mar 17, 2011 6:04 pm
Location: San Diego, CA, US

Re: Extra Battery, How to Integrate with 24kWh Traction Battery?

Sun Oct 01, 2017 7:26 pm

Is the LEAF OBC able to charge both packs or are you forced to charge them separately?
2014 Rav4 EV, Blizzard Pearl White
2011 LEAF SL w/QC, Blue Ocean, returned at end of lease

User avatar
Marktm
Gold Member
Posts: 345
Joined: Thu Jan 21, 2016 10:49 am
Delivery Date: 09 Jan 2016
Leaf Number: 022737

Re: Extra Battery, How to Integrate with 24kWh Traction Battery?

Mon Oct 02, 2017 6:34 am

Atkam wrote:Finally I finish with full integration my additional battery parallel with main battery. I expect additional 100-150 km. Testing is in progress. Please find below some sample picture.
thank you: turbo3, gerygid, leaf xpack, jehugarcia, Njah kavin, HBPowerwall, Damien Maguire, Wolf Tronix, mikeatyouttube and many others which gave me useful information for this hobby project.


Atkam;
Based on your work, do you have any ideas/suggestions on this hobby project:
- Goal is to use the Leaf's HV battery to power a ~400 VDC 8kw UPS for emergency power (240 VAC single phase).
- The UPS will supply split phase power to a sub-panel using a center tapped iso transformer.
- HV power wiring to be connected at the PTC heater (gutted) and routed to a protected quick connect/disconnect (Andersons) for convenience of connecting to the UPS. This circuit (2012 Leaf), is fused at 30 amps/400 VDC - should be OK from a protection aspect?
- The Leaf will have to be left in "start" mode, but I'd like to remove (defuse) as many "parasitic" loads possible.
- Charging to be conventional AC Level II (240 VAC) for now (I have an arduino/solar system set up to do this).
- I do want to be able to drive the Leaf out of "solar" area and use it with very little effort (basically disconnect the Andersons).

My worry is "bricking" the Leaf (at a rather rural area) as a result of connecting/disconnecting/operating in this "emergency" power supply mode. Do you have any comments/suggestions?

Great project work - such learning experiences are amazing!
2012 Leaf SL; 36,000 miles. Battery replaced November 1st, 2016.
Rural cabin with 6750 watts Grid tied PV. Off-grid solar Leaf charging capable (level II).

RNM
Posts: 41
Joined: Mon Feb 29, 2016 10:11 am
Delivery Date: 05 Mar 2016
Leaf Number: 012707

Re: Extra Battery, How to Integrate with 24kWh Traction Battery?

Mon Oct 02, 2017 11:54 am

Atkam wrote:Finally I finish with full integration my additional battery parallel with main battery. I expect additional 100-150 km. Testing is in progress. Please find below some sample picture.
thank you: turbo3, gerygid, leaf xpack, jehugarcia, Njah kavin, HBPowerwall, Damien Maguire, Wolf Tronix, mikeatyouttube and many others which gave me useful information for this hobby project.


ATKAM,

Can you share a more about this mod?
A whole year has passed but you didn't share anything with us :)
thanks!

Atkam
Posts: 5
Joined: Fri Jan 16, 2015 3:33 am
Delivery Date: 16 Feb 2015

Re: Extra Battery, How to Integrate with 24kWh Traction Battery?

Thu Oct 05, 2017 1:56 pm

Some additional information of my integration:
1. I integrate secondary battery 22p96s, 6 box - each box 16 block with 22p 18650 cells.
2. I'm connected in line with the big power wires coming out of the main pack.
3. I have 3 tyco contactors to connect primary and secondary pack together
4. I've tapped the power wires going to the main pack's contactors so I know when they're closed
5. I use 1 x arduino uno and one arduino mega for controlling 3 tyco contactrs
6. I have a several controlling mechanism delta V, delta T, state of contactor, ..
7. Second battery is charging same time as primary battery, CHADEMO charging not tested yes (probbaly I need some ressitor serial to protect to high current at first coiple of charging with CHADEMO...
I need find some time for put all schematic and diagram together because I work without plans. I have only hands-free sketches of plans and it takes a lot of time to prepare these plans in a decent format.

br
Ales

Atkam
Posts: 5
Joined: Fri Jan 16, 2015 3:33 am
Delivery Date: 16 Feb 2015

Re: Extra Battery, How to Integrate with 24kWh Traction Battery?

Thu Oct 05, 2017 2:02 pm

Marktm wrote:
Atkam wrote:Finally I finish with full integration my additional battery parallel with main battery. I expect additional 100-150 km. Testing is in progress. Please find below some sample picture.
thank you: turbo3, gerygid, leaf xpack, jehugarcia, Njah kavin, HBPowerwall, Damien Maguire, Wolf Tronix, mikeatyouttube and many others which gave me useful information for this hobby project.


Atkam;
Based on your work, do you have any ideas/suggestions on this hobby project:
- Goal is to use the Leaf's HV battery to power a ~400 VDC 8kw UPS for emergency power (240 VAC single phase).
- The UPS will supply split phase power to a sub-panel using a center tapped iso transformer.
- HV power wiring to be connected at the PTC heater (gutted) and routed to a protected quick connect/disconnect (Andersons) for convenience of connecting to the UPS. This circuit (2012 Leaf), is fused at 30 amps/400 VDC - should be OK from a protection aspect?
- The Leaf will have to be left in "start" mode, but I'd like to remove (defuse) as many "parasitic" loads possible.
- Charging to be conventional AC Level II (240 VAC) for now (I have an arduino/solar system set up to do this).
- I do want to be able to drive the Leaf out of "solar" area and use it with very little effort (basically disconnect the Andersons).

My worry is "bricking" the Leaf (at a rather rural area) as a result of connecting/disconnecting/operating in this "emergency" power supply mode. Do you have any comments/suggestions?

Great project work - such learning experiences are amazing!


ATKAM
Interesting plan. My question how to get a DC/AC for 400V DC to 240VAC converter. I already looking and not find it. I thing is very interssting project because cover emergency power for home.. I have a similar plan to V2H. Free of charge car, drive to home and power supply home,... :)

User avatar
Marktm
Gold Member
Posts: 345
Joined: Thu Jan 21, 2016 10:49 am
Delivery Date: 09 Jan 2016
Leaf Number: 022737

Re: Extra Battery, How to Integrate with 24kWh Traction Battery?

Thu Oct 05, 2017 2:55 pm

Atkam wrote:Interesting plan. My question how to get a DC/AC for 400V DC to 240VAC converter. I already looking and not find it. I thing is very interssting project because cover emergency power for home.. I have a similar plan to V2H. Free of charge car, drive to home and power supply home,... :)


I own a SRT10K UPS inverter that operates at ~400 VDC. The issue for me is (admittedly) not enough confidence that I will not "brick" my Leaf by wiring it to the PTC heater circuit (that has a 30 amp fused circuit) and "firing up" the Leaf. To use the SRT10K for household split phase circuits, I have a 5K watt center tapped iso-transformer. I bought the Leaf to do that, then realized I would likely get a new battery and enjoyed driving it so much, I've put off the "experiment". I have done something similar with a Prius traction battery and a SURT6000 UPS (at ~ 200 VDC) and it has worked very well as an emergency generator.

If I find a cheap/used PTC heater for a 2011/12 Leaf, I'll actually do it.
2012 Leaf SL; 36,000 miles. Battery replaced November 1st, 2016.
Rural cabin with 6750 watts Grid tied PV. Off-grid solar Leaf charging capable (level II).

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