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Unread 11-26-2017, 03:33 PM   #1
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Default Club Car Onward Leaf Lithium conversion

I took the first step today in building my lithium pack so I figured it was time to start the build thread.

Itís not Ďreallyí step #1 since I think sourcing all of the build materials should be considered steps, but it is step 1 of the actual installation I suppose.

Extend leads on BMS temp sensor and silicone to the side of the cell module. Once it is dry, bolt the cells together.





Iím using 2 temp sensors only, in between module 1 and 2, then 3 and 4.


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Unread 11-27-2017, 01:37 PM   #2
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Default Re: Club Car Onward Leaf Lithium conversion

This ought to be a great thread E36!

I think many here are looking to go this way, I am.
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Unread 11-27-2017, 03:56 PM   #3
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Default Re: Club Car Onward Leaf Lithium conversion

Will be watching this thread closely too. How many Volts and Amp Hours?
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Unread 11-27-2017, 05:12 PM   #4
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Default Re: Club Car Onward Leaf Lithium conversion

Since there seems to be a few people interested in this build, let me back up to the beginning. I'm pretty sure I'm the first to do a lithium conversion on a Club Car Onward, but it's basically a Precedent so I don't know if that is really relevant.

First and foremost, I need to thank Furyus for convincing me to pull the trigger. And I also need to thank PingEye3 for helping me with some technical questions on the BMS and also making me the end plates to mount the pack (in addition to Anderson connectors and just over pack design). Without the help from both of them I probably would have pushed it off until my batteries were dead in 5 or 6 years and I'm sure lithium conversion kits will be readily available by then. Plus, thank you to everyone that has already posted a lithium thread, I've read them all about 15 times and they have been very educational. At first I was nervous because I have Lipo experience in the RC world and carts are much more complex. But at the end of the day, the concepts are the same, it's just the hardware is slightly different. Frankly, if someone would make a charger with a built in balancer like in RC, the conversion would be a piece of cake. No real need for a BMS at that point.

It all started when Furyus found a local guy that bought an entire pack from a totaled 2016 Nissan Leaf with 5,265 miles for a conversion on his Gem. So I picked up 4 of the 4 cell 82ah modules (total of 16 cells) and was able to buy in person and not deal with shipping. I paid $300/module. Since my Alltrax XCT48500 can only handle a max of 60 volts, I plan to use only 14 cells and have a 58v pack.

Since Nick at EV battery has been having health issues I started searching for hours online to come up with other BMS and charger options. The one thing I wanted out of the BMS was a unit that did not require the use of a cell phone to change settings, monitor pack voltage, state of charge, etc., since my wife will use the cart and there is no way having to use the phone will fly with her. I needed a very simple interface. Since digital volt meters are not as relevant as the state of charge ("SOC") for lithium packs, I needed a dash mount SOC meter so wifey knows how much gas is still in the tank. Basically I need to keep the cart as simple to use and operate as it was they day it was delivered from Club Car.

That ultimately led me to ZEVA.com.au, as they are the only BMS system I could find with a panel/dash mount LCD screen. The LCD is also touch screen to adjust all of the settings on the BMS as well, so I considered that a win/win. The guy from Zeva (Ian) suggested I use a charger from TC chargers (aliexpress.com) because they have a CAN bus port so the BMS will talk directly to the charger and I can adjust charging voltages, stop points, amperage, ect. The charger was built specifically for me by TC and arrived today 11/27. Total cost of the BMS and charger with shipping was in the ballpark of $750. Not the cheapest option out there, but not the most expensive either. I'd say it's in the middle of the road.

One challenge I'm still not 100% on how I'm going to proceed is the fact that the BMS runs on 12v. I have a factory reducer for the stock lighting and also a stand alone 12v battery for my LEDs and stereo amps. Ian from Zeva suggested that I parallel the 12v reducer to the 12v battery. However, I might just rewire the amps to the reducer and use the 12v battery on the BMS alone. But I'll cross that bridge when I get there. Next step (hopefully tonight) is to get the actual pack assembled now that the temp probes are glued to the cells.

More to come as things progress. I'll do my best to be as detailed as possible. Don't hesitate to ask me any questions.
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Unread 11-27-2017, 09:46 PM   #5
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Default Re: Club Car Onward Leaf Lithium conversion

Pack assembled. One thing worth noting is that itís easier to stack on its side facing up. The cells get a little heavy after the first two modules are on the all-thread. Plus the 1/4Ē all-thread isnít a perfect fit so it has to be finessed through. Since I donít have a bench grinder to clean up the ends from cutting the all-thread I installed acorn nuts which also are insurance on the nylon lock nuts.



Tomorrow I hope to get the bars on and the BMS tap harness installed.


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Unread 11-28-2017, 11:47 AM   #6
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Default Re: Club Car Onward Leaf Lithium conversion

Following.

Thanks for the great explanation so far.
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Unread 11-28-2017, 12:53 PM   #7
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Default Re: Club Car Onward Leaf Lithium conversion

Very nice looking pack ! Not even sure this applies? but-
Have you contacted your manufacture to inquire if extending the temp sensor wires will effect the sensor performance ? All of the research and inquiries I did on motor temp sensors said the sensor and the read out were calibrated with the length of the lead and that adding to the length would ill effect the reading.
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Unread 11-28-2017, 03:39 PM   #8
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Default Re: Club Car Onward Leaf Lithium conversion

Following too. Looking to do this when the lead wears out.
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Unread 11-28-2017, 03:48 PM   #9
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Default Re: Club Car Onward Leaf Lithium conversion

I'm watching....
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Unread 11-28-2017, 05:29 PM   #10
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Default Re: Club Car Onward Leaf Lithium conversion

Quote:
Originally Posted by scottyb View Post
Very nice looking pack ! Not even sure this applies? but-
Have you contacted your manufacture to inquire if extending the temp sensor wires will effect the sensor performance ? All of the research and inquiries I did on motor temp sensors said the sensor and the read out were calibrated with the length of the lead and that adding to the length would ill effect the reading.


The stock leads were like an inch.... Zeva said just extend them, but I see your point. Iíll have to follow up about it. There is also the possibility that they donít need to be 100% accurate in this application.


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