A1exander
Posts: 5
Joined: Mon Jul 20, 2020 2:49 pm
Delivery Date: 20 Jul 2020
Leaf Number: 015815
Location: Linköping, Sweden

Total battery rebuild! Almost done - but help needed - solved!

Mon Jul 20, 2020 3:23 pm

Hi!
I saw a YouTube video of a guy in Ukraine who swapped all cells in his battery pack to lg chem NMC 60ah cells... This means approximately 40kwh of useable energy... So I got inspired and decided to do the same thing! I mean, how hard can it be...? I have a 2012/2013 Nissan Leaf (gen 1 battery pack).

First, I bought 200 cells (to have 8 spares), put them into packs of 2 cells, constructed aluminum connectors between the cells, put cables to all individual packs for balancing and... then I removed my pack and opened it. I measured the voltage to all cells to make sure I marked all balancing cables the right way, to make sure I connected them all correctly eventually... then I put all cells into the battery pack, re-connected all temperature sensors, heaters... and today, finally, I put the pack back into the car. Leafspy showed a nice balanced pack - the balancing cables must have been connected correctly (despite how ugly my wiring looks)! But now, here comes the problem. The car did not start, and the battery didn’t want to charge. Eventually I checked error codes and after clearing the codes, four remained. And this is where I need help. My guess is that P32E1 (HV system interlock error) is the code that causes me troubles. I also see this information in Leafspy that I don’t understand. Have I, after all, done something wrong when it comes to wiring? Shouldn’t be the case with LeafSpy showing all cell voltages, though... too high resistance somewhere?
No voltage on the main battery connector on the outside of the battery.

Any thoughts?

Thank you so much in advance! I will post pictures when I figure out how to...

Best regards,
Alexander from Linköping, Sweden
Last edited by A1exander on Fri Jul 24, 2020 1:12 am, edited 2 times in total.

coleafrado
Posts: 291
Joined: Fri Oct 11, 2019 11:58 pm

Re: Total battery rebuild! Almost done - but help needed!

Mon Jul 20, 2020 7:50 pm

Did you accidentally unplug the service disconnect sensor cable?

A1exander
Posts: 5
Joined: Mon Jul 20, 2020 2:49 pm
Delivery Date: 20 Jul 2020
Leaf Number: 015815
Location: Linköping, Sweden

Re: Total battery rebuild! Almost done - but help needed!

Mon Jul 20, 2020 10:47 pm

That might actually be the cause... I went through the pictures I took, and it looks like a black connector with 2-wires that is connected on the bottom of the holder for the service plug, (and on google on later models the connection seems to be just outside of the holder instead) and I don’t remember neither unplugging or plugging that cable, but I can see a cable on that position in my pictures... I will try to drop the battery tonight and have a look at it. Thank you in advance!

coleafrado
Posts: 291
Joined: Fri Oct 11, 2019 11:58 pm

Re: Total battery rebuild! Almost done - but help needed!

Tue Jul 21, 2020 9:20 am

How much were the cells, by the way? This sounds very similar to what EV Battery Rebuilds in Spain did, but they indicated it was not very economical.

A1exander
Posts: 5
Joined: Mon Jul 20, 2020 2:49 pm
Delivery Date: 20 Jul 2020
Leaf Number: 015815
Location: Linköping, Sweden

Re: Total battery rebuild! Almost done - but help needed!

Tue Jul 21, 2020 4:32 pm

It worked! Thank you! I had forgotten that cable...! I am now charging the car, and have also went for a short ride in it and so far so good. No error codes. I will go for a longer ride tomorrow to see how it all works.

I paid, all in all, about 5000 USD. And then I have all my original cells left, to do whatever I want with them... It was however pretty time consuming. Of course I have never done this before, but all in all I probably put around 100 hours into this project... If I were to do it again I might be able to do it in about half that time, but that is still a lot of time.

coleafrado
Posts: 291
Joined: Fri Oct 11, 2019 11:58 pm

Re: Total battery rebuild! Almost done - but help needed!

Tue Jul 21, 2020 9:17 pm

A1exander wrote:
Tue Jul 21, 2020 4:32 pm
It worked! Thank you! I had forgotten that cable...! I am now charging the car, and have also went for a short ride in it and so far so good. No error codes. I will go for a longer ride tomorrow to see how it all works.

I paid, all in all, about 5000 USD. And then I have all my original cells left, to do whatever I want with them... It was however pretty time consuming. Of course I have never done this before, but all in all I probably put around 100 hours into this project... If I were to do it again I might be able to do it in about half that time, but that is still a lot of time.
Congrats!

Steelcity
Posts: 27
Joined: Wed May 13, 2020 5:31 am
Delivery Date: 13 Jun 2013
Location: Pittsburgh

Re: Total battery rebuild! Almost done - but help needed!

Wed Jul 22, 2020 3:38 am

Hats off to ya. Great job. Where did u source the cells from ? And what chemistry?
2013 S Bought used 2020 33,000 11 bars
Led headlights
4.8 miles per kwh
4.9 miles per kWh (8/14/20)
5.0 miles per kwh (9/30/20)

A1exander
Posts: 5
Joined: Mon Jul 20, 2020 2:49 pm
Delivery Date: 20 Jul 2020
Leaf Number: 015815
Location: Linköping, Sweden

Re: Total battery rebuild! Almost done - but help needed!

Thu Jul 23, 2020 4:52 pm

Thank you! It’s been working pretty well, and I am over all very happy with the outcome, but the cells aren’t perfectly balanced (about 70mv off at the moment). I hope they will balance over time, otherwise I will change affected cells eventually or something similar, since I have 8 spares. I have now driven about 300km (approx. 200 miles) so far without any issues.

I bought the cells from alibaba.com, so China, but imported from South Korea (cells are supposed to be 60 AH LG NMC cells, and seem legit). Only problem with the NMC chemistry is that a large amount of the energy is stored at a lower voltage than the original cells (LMO chemistry, right?), which means about half of the energy is left when the car says it is out of juice. So the “guess-o-meter” is pretty off, but in the right direction anyway.

brunohill
Posts: 24
Joined: Thu Jan 03, 2019 10:36 pm
Delivery Date: 05 Oct 2017
Location: VK3

Re: Total battery rebuild! Almost done - but help needed - solved!

Wed Aug 19, 2020 4:18 pm

How is the cell balancing going ? Have you had problems with it hitting turtle mode when under load ?

A1exander
Posts: 5
Joined: Mon Jul 20, 2020 2:49 pm
Delivery Date: 20 Jul 2020
Leaf Number: 015815
Location: Linköping, Sweden

Re: Total battery rebuild! Almost done - but help needed - solved!

Fri Aug 21, 2020 12:09 pm

The balancing is slightly off, still one “module” (pair of cells) that is about 50mv off when fully charged. That means I can’t charge the last 5-7% or so of the rest of the battery pack... so I might end up changing that pair some time.

Nope. Never hit turtle mode so far, even during full load after 200km driving. But I can’t really use the guess-o-meter at all. When it says the battery is dead, I have more than half left. So far, the longest I have driven has been slightly over 200km, and I would guess I had at least 20% capacity left. But I would say I’m pretty satisfied with approximately 200-250km range with normal driving. I’ve used the car for a bit more than 3000km after the battery rebuild with no issues so far. :)

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