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Unread 06-26-2019, 07:34 AM   #31
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Default Re: Let's see your lithium boxes!

Quote:
Originally Posted by somfas View Post
Do the Gen 1 Leaf Modules need any spacers or washers between each module?
Also, what ambient temps are okay for these batteries in the cart? They will be cruising around and be parked in 100 degree heat sometimes. Wont get much cold time though. Thanks!
Not 100% sure, but I don't believe it is necessary to have spacers between each module. My pack does not, however I have Gen 2 modules. I will say that the stock spacers with the studs on top, make for a nice way to fabricate a cover over the pack.

Here is a link to a specific post on a thread to answer your question on temperature: 48volt club car limthium battery exploded The post is from Sergio, he knows his stuff on all of this lithium!

If you have not already, it would be a good thread to read through anyway. There is a lot of good information shared on it.
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Unread 06-26-2019, 07:40 AM   #32
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Default Re: Let's see your lithium boxes!

It depends on the generation of the Leaf module, if there is a recessed shape for the spacer then it is absolutely necessary.

The Leaf modules are designed to be tight around the corners and the enclosure shape works like a "spring washer" to keep the designed pressure on the pouches.

Removing the spacers would allow for too much compression on the module corners and that would affect the design specification for module.

Notice the difference between the modules below and how the corners are recessed on the bottom one.

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Unread 06-26-2019, 09:38 AM   #33
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Default Re: Let's see your lithium boxes!

Thanks! I thought they needed them. I had to use two washers combined for each of the four holes for two of the modules. The rest have the factory ones. Plus, I have them on each end plate. I have posted pictures on this forum before but I sure can't figure it out now. I have attached links to the items I am using. I hope they work.

https://www.google.com/search?q=leaf...LANEvN6L_HkKM:



https://www.google.com/search?q=leaf...anUJaDxpqWC2M:
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Unread 07-17-2019, 11:56 PM   #34
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Default Re: Let's see your lithium boxes!

Thanks to everyone posting their projects and expertise on diy lithium conversion, this forum is a great resource for the engineering challenged!

These are my initial pictures - sorry about the rotation.

I wanted to have the main pack and bms isolated as much as possible so that I only have to dsconnect the main anderson connector and the CAN connections if I need to remove the leaf modules or upgrade the pack to 14.
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Unread 07-18-2019, 07:18 AM   #35
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Default Re: Let's see your lithium boxes!

Very nice and clean box you've made.

I take it your main pack positive will run vertically up through the Hall sensor and towards the back of the pack? Where will you connect the Anderson connector at then?

BTW, where did you source that thick acrylic? How thick is it?
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Unread 07-18-2019, 08:58 AM   #36
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Default Re: Let's see your lithium boxes!

I can't tell if the back side is covered or not. I'm just thinking about air flow and ventilation. If it's not covered all would appear to be good. If it is covered, I'd consider a small hole saw to cut a few air flow holes....perhaps in the back corners.

FWIW
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Unread 07-18-2019, 09:30 AM   #37
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Default Re: Let's see your lithium boxes!

That's a cleanly built and well protected pack. My concern would be lack of ventilation as well. As long as you install a thermometer to keep an eye on it I think you will be fine. If heat build up is an issue you can always install a small computer style case fan to pull some air across the pack.

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Unread 07-19-2019, 11:34 AM   #38
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Default Re: Let's see your lithium boxes!

Thanks, even after reading everyone's posts I know I'll still be looking for help when I try to connect everything in the cart.

Yes - I plan to run the terminals out the back and probably attach the andersen to the side.

Found the acrylic at Lowes, its 7/32", not sure if it was a regularly stocked item or not.

I have been worried about heat, especially during the summers here on the SC coast. I left the back open and the lower part on the front open hoping that would give me enough airflow, but I'll need to monitor the temp for sure.
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Unread 07-19-2019, 01:10 PM   #39
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Default Re: Let's see your lithium boxes!

Quote:
Originally Posted by DoraCell View Post
I have been worried about heat, especially during the summers here on the SC coast. I left the back open and the lower part on the front open hoping that would give me enough airflow, but I'll need to monitor the temp for sure.
Maybe a couple of 12v computer style fans to pull / push the air out ?
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Unread 07-19-2019, 01:39 PM   #40
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Default Re: Let's see your lithium boxes!

Also make sure You install a temperature sensor on the middle of the pack and connect it to the Zeva BMS.
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