DaveinOlyWA
Posts: 14611
Joined: Sat Apr 24, 2010 7:43 pm
Delivery Date: 16 Nov 2019
Leaf Number: 319862
Location: Olympia, WA
Contact: Website

Re: Battery Upgrades are very possible

Wed Jan 01, 2020 10:52 am

Daklein wrote:
Wed Jan 01, 2020 9:52 am
MikeD wrote:
Wed Jan 01, 2020 4:40 am
Congratulations!: Do you expect that you will normally charge up to ~80% (for battery pack health) when you expect not to need the maximum range during a given day?
Yes, I think we'll charge to a lower SOC normally, 50% would do more than our typical use now. If we're going further and depending on where we're going, charge more at home, or stop at a fast charger.
My E Plus lives between 20 to 70% 90% of the time. Highest overnight SOC; 74%. Highest SOC negating delivery day; 88% (during 150 trip)

I have yet to use home charging. I have all but decided I probably won't until my NCTC runs out next month. No real reason to do so. With enough range to do my entire 4 day weekly commute, I simply stop and charge when its convenient.
2011 SL; 44,598 mi, 87% SOH. 2013 S; 44,840 mi, 91% SOH. 2016 S30; 29,413 mi, 99% SOH. 2018 S; 25,185 mi, SOH 92.23%. 2019 S Plus; 4411.3 mi, 96.88% SOH
My Blog; http://daveinolywa.blogspot.com" onclick="window.open(this.href);return false;

Daklein
Posts: 66
Joined: Fri Sep 06, 2019 7:58 pm
Delivery Date: 02 Sep 2019
Location: Hartland, MI

Re: Battery Upgrades are very possible

Fri Jan 03, 2020 9:33 pm

I took a drive today after putting everything back together. 75 miles and it's still about half full, and didn't start from full either, Boy it's crazy having that much range. A little bug with fast charging though, the car tells the charger it's already full and it stops right away, so some figuring to do on that.

The original covers are on; some of the screw and push pin holes lined up right at the front and the rear of the pack. In the rest of it, I made new holes in the covers to line up with existing mounting points on the 62 pack. They're not perfect by any means; they are not quite wide enough and don't wrap upwards since the battery is lower underneath. I may add something along the sides to keep spray from blowing up in there. The front cover worked ok with some trimming, it will keep the cables protected.

There's a little less ground clearance for sure. And it might be riding lower too from the extra weight, looking at the fender gaps. Feels great driving though, but that might be coming primarily from having such a high number on the GOM!
2014 Leaf S Plus :o (12/2019 62kWh swap!)

Oilpan4
Posts: 1247
Joined: Wed Jan 09, 2019 10:51 pm
Delivery Date: 10 May 2018
Leaf Number: 004270

Re: Battery Upgrades are very possible

Sat Jan 04, 2020 8:48 am

Daklein wrote:
Fri Jan 03, 2020 9:33 pm
I took a drive today after putting everything back together. 75 miles and it's still about half full, and didn't start from full either, Boy it's crazy having that much range. A little bug with fast charging though, the car tells the charger it's already full and it stops right away, so some figuring to do on that.

The original covers are on; some of the screw and push pin holes lined up right at the front and the rear of the pack. In the rest of it, I made new holes in the covers to line up with existing mounting points on the 62 pack. They're not perfect by any means; they are not quite wide enough and don't wrap upwards since the battery is lower underneath. I may add something along the sides to keep spray from blowing up in there. The front cover worked ok with some trimming, it will keep the cables protected.

There's a little less ground clearance for sure. And it might be riding lower too from the extra weight, looking at the fender gaps. Feels great driving though, but that might be coming primarily from having such a high number on the GOM!
My car does that too. Have you tried a different chademo?
I only have access to 1 and I'm pretty sure it's the chademo.
2011 white SL leaf with 2014 batt.
Chargers: Panasonic brick moded for 240v, duosida 16a 240v and a 10kw setec portable CHAdeMO
Location: 88103

knightmb
Posts: 466
Joined: Mon Jan 12, 2015 7:41 pm
Delivery Date: 15 Sep 2013
Leaf Number: 414897
Location: Franklin, TN

Re: Battery Upgrades are very possible

Sat Jan 04, 2020 9:22 am

Daklein wrote:
Fri Jan 03, 2020 9:33 pm
I took a drive today after putting everything back together. 75 miles and it's still about half full, and didn't start from full either, Boy it's crazy having that much range. A little bug with fast charging though, the car tells the charger it's already full and it stops right away, so some figuring to do on that.
Does the QC start and just "finish" with no error or does the CHAdeMO spit back some error code while starting?
2013 Leaf SV

mux
Posts: 267
Joined: Sat Jan 13, 2018 3:52 am
Delivery Date: 13 Oct 2011
Leaf Number: 6177

Re: Battery Upgrades are very possible

Sat Jan 04, 2020 10:59 am

It was a known issue with our firmware for 40kWh swaps, I recently fixed it (at least for the 40kWh swap on DBT fast chargers) and hopefully that fix will work for Daklein too. He's compiling and flashing the latest version shortly I think.

The reason this happens is that DBT, Efacec and possibly some other chargers are programmed to terminate a charge at 100% indicated charge level. The Leaf has 4 (!) internal SOC states, two of which we modify with our firmware and two of which until recently were either unmodified or wrong in some sense. The car interprets those values as 100% (or, well, more than 100% if the new battery capacity is way more than the car is programmed to handle), forwards this over QC CAN and then the charger thinks 'hey, why are you trying to charge, you're full already!' and either fails the charge with a communication error or initiates and immediately stops the session.

As the three sub-generations of Nissan leaf with the old body style all use a slightly different way to calculate and display SOH in various places, this is a bit of a headache to properly fix. It is also fundamentally unfixable on the first generation (2010-13), so we employ a workaround that messes with Leaf Spy Pro data.

MikeD
Posts: 701
Joined: Thu Jun 24, 2010 6:14 am
Delivery Date: 12 May 2011
Leaf Number: 592

Re: Battery Upgrades are very possible

Sat Jan 04, 2020 12:21 pm

mux: Bottom line question: is it going to be possible to upgrade 24kWh Leafs via a simple 40kWh battery pack swap together w/ a gateway device?

mux
Posts: 267
Joined: Sat Jan 13, 2018 3:52 am
Delivery Date: 13 Oct 2011
Leaf Number: 6177

Re: Battery Upgrades are very possible

Sat Jan 04, 2020 1:04 pm

Yes, we have already done this with 5 cars now and are working out the last few smaller issues. I'm sure there will be further minor issues down the line, but it's about as close to a plug&play solution as it gets considering you have to remount a 600lb battery.

knightmb
Posts: 466
Joined: Mon Jan 12, 2015 7:41 pm
Delivery Date: 15 Sep 2013
Leaf Number: 414897
Location: Franklin, TN

Re: Battery Upgrades are very possible

Sat Jan 04, 2020 6:15 pm

Best news I've read this year! :mrgreen:
Is the gateway device easily upgradable should you need to make future tweaks? At least in the sense that it can upgraded some other way than device replacement.
2013 Leaf SV

Daklein
Posts: 66
Joined: Fri Sep 06, 2019 7:58 pm
Delivery Date: 02 Sep 2019
Location: Hartland, MI

Re: Battery Upgrades are very possible

Sat Jan 04, 2020 6:57 pm

Yes, it is reflashable with an AVR Isp programmer, and it has a serial port that will allow configuration or option selections, and some limited data logging (no storage, just collect data while connected).
2014 Leaf S Plus :o (12/2019 62kWh swap!)

Daklein
Posts: 66
Joined: Fri Sep 06, 2019 7:58 pm
Delivery Date: 02 Sep 2019
Location: Hartland, MI

Re: Battery Upgrades are very possible

Sat Jan 04, 2020 8:23 pm

I plan to try reflashing the bridge after Monday.  I have a longer trip to do, and with the big battery I don't need to stop for fast charging.  But also don't want to goof up the car before then.  I signed up for the next level of AAA towing insurance, free tows up to 100 miles, because I already paid for a 100 mile tow (youch!) after my PTC heater & precharge resistor adventures.  So I'm good to go for testing no matter what happens.       

I did figure out a solution for the battery covers that won't be too ugly and will be better splash protection than the OEM covers.  Using the old pack covers with some more modification, and added strips along the rocker panels.  Hope to finish it up tomorrow.    

I charged it until it stopped today.  I was underneath when the contactors clicked off.  The pack voltage was 395.0 after charging stopped, so the ending at 396 did worked as intended, I guess about 1V of sag back without charging current. 

Showed 89 pct, 213 miles on the GOM.  https://photos.app.goo.gl/pLBE47KmEiT7Re1dA
2014 Leaf S Plus :o (12/2019 62kWh swap!)

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