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-   -   leaf mondules conversion issues (http://www.buggiesgonewild.com/lithium-club-car/150072-leaf-mondules-conversion-issues.html)

poltergiest 02-11-2019 07:53 AM

leaf mondules conversion issues
Well having an issue with my conversion. I am converting from a 16s lifepo4 to 7 leaf modules and am running into issues with range.

I saw one say they went 14 miles and 4 wot and used 1V. I go 2 miles and use 1V and only half throttle. 4 miles and 4V!

I got the cells and brought them all down to 2.9V and connected them in series and charged them up to 4.15V.

I am using the conversion kit from ScottyB for my 2003 club car DS, but I think maybe I did not get the correct controller now, its not an altrax 500 but a FSIP.
Anyway it worked well on the lifepo4 pack.
I have 12 inch tires, plumquick bandit, scottyB c54 kit.

We made sure all the connectors were cleaned up from rust (I live one house from the sea).
The brakes are not dragging, or least not in the air.
My resistor and diodes legs are rusty could that cause a larger draw?

So where to start troubleshooting this?


Volt_Ampere 02-11-2019 08:40 AM

Re: leaf mondules conversion issues
YOu probably want a 14 leaf module setup if you are concerned at all with range. You are only going to get maybe 10 miles range with a 7 module setup and you have to be careful not to push it or you will overdischarge the cells.

Sergio 02-11-2019 09:23 AM

Re: leaf mondules conversion issues
What happened to your existing 16s lifepo4 setup?

NoleFan4Ever 02-11-2019 10:31 AM

Re: leaf mondules conversion issues
I have made two (2) long trips of approximately 20 miles on my 7 module pack as designed below. This was casual driving and relatively flat ground. On stop and go driving it does deplete the pack faster just due to the energy exerted to get the cart moving and up to sustained speed again.

We also have a Chevy Volt pack in service and it gets a little less. I have had no need to go to a 14 module pack since the 7 has easily met my needs. :thumbup:

Volt_Ampere 02-11-2019 11:47 AM

Re: leaf mondules conversion issues
When I use my cart for golf I easily get 3 rounds on my 14 module pack without pushing it but that is only about 18 miles. Stop and go uses more juice for sure.

poltergiest 02-11-2019 09:12 PM

Re: leaf mondules conversion issues
my solar panel rusted the connections off, so it stopped working. Then the plug in charger died, when that happened I forgot to disconnect the battery and the solar controller drew the battery pack down over the two months it took to get another panel and charger to me. Two cells went below 2.0v, so not good.
I go with bottom balancing and in this case it got me, but entirely my fault.

I try not to use the brake and have become pretty good at feathering the GO pedal. But even when it is more or less at 1/4 or 1/2 throttle with zero stops I still get bad mileage. 6 miles at aprx. 15-18mph is all.

Sergio 02-12-2019 08:05 AM

Re: leaf mondules conversion issues
I would start by measuring the individual cells when the pack is discharged to make sure they are still balanced.

The 2.9v is a good voltage to bottom balance as it is below the knee of the discharge curve, however the voltage bounces a lot at that region depending on the load used to bring the cell voltage down.

Did you do an automated setup using a JLD5740 (or JLD404) type meter to bottom balance?

Those work really nice for bottom balancing and later you can use the meter to provide LVD and HVD for the pack so you don't run into those accidents like it happened to your previous pack.

poltergiest 02-13-2019 09:24 AM

Re: leaf mondules conversion issues
I used 2.9v as the bottom using powerlab8. I think I used 5a to draw them down.

Maybe I should think about that JLD5740. Will it stand up to being outside 24/7? I have no garage at the condos.

What else would you recommend ordering with it?

Sergio 02-13-2019 09:54 AM

Re: leaf mondules conversion issues
The powerlab8 is the perfect tool for bottom balancing so you are probably good with that one.

Just for LVD and HVD the JLD404 is cheaper and the precision is good for the whole pack voltage.

The instructions are somewhat hard to understand, but it provides two sets of SPDT relay outputs that can be used at different voltage levels to provide the low and high safety disconnects:
The unit is not waterproof, but one member here mounted inside one of those inexpensive radio dash waterproof hinged covers and it works and looks good inside.

Edit: Correction, the JLD404 is not cheaper if all you want is to monitor voltage (no current shunt).
Manual: http://media3.ev-tv.me/Voltmeter.pdf

poltergiest 02-22-2019 03:56 PM

Re: leaf mondules conversion issues
I have a couple shunts here both are 500a.

So to get LVD and HVD which would you think the 404 or 5740?

Sorry life got to me...having shoulder surgery next week, yay.

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