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Unread 09-13-2018, 01:19 PM   #61
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Default Re: Bit the bullet Leaf Lithium build

Quote:
If You are installing on a Sepex with Regen cart, only use the relay for the key switch interrupt and run the other LV terminal to the Zeva HV terminal. The other HV terminal goes to pack negative.

That will allow the Zeva to disable the cart on a high cell voltage condition (Regen) as well.
My cart is an EZ-GO TXT series. And I have no regen connected up. (When your going down hill......it's all freewheeling!!.....and this is why I have front disc brakes!!!)

I again, thank you for the detailed information!!

Dave
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Unread 09-13-2018, 01:25 PM   #62
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Default Re: Bit the bullet Leaf Lithium build

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Originally Posted by Sergio View Post
For the LV and HV cutoff, I would use these type of relays:
http://www.mouser.com/access/?pn=T9AP1D52-48-01

For the HV relay:
Run the charger positive output to one side of the relay coil and to the relay COM terminal.
Connect the other side of the relay coil to the Zeva HV terminal.
Connect the relay NO terminal to the current shunt before the battery.

For the LV relay:
Disconnect the wire(s) from the "cold" side of the key switch.
Run a new wire from the "cold side" of the key switch to one side of the relay coil and to the relay COM terminal.
Connect the other side of the relay coil to the Zeva LV terminal.
Run a new wire from relay NO terminal to the wire(s) that were originally connected to the Key switch "cold" side.
Connect the two open terminals from the Zeva LV and HV to the pack negative.

If You are installing on a Sepex with Regen cart, only use the relay for the key switch interrupt and run the other LV terminal to the Zeva HV terminal. The other HV terminal goes to pack negative.

That will allow the Zeva to disable the cart on a high cell voltage condition (Regen) as well.
Shouldn't they really be high amperage and low amperage, rather than high and low voltage?
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Unread 09-13-2018, 01:42 PM   #63
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Default Re: Bit the bullet Leaf Lithium build

DaveTM, I added the comment about Sepex since other folks posting on this thread are using their Leaf packs on Sepex drives.

yurtle, the LV and HV terminology is what is on the Zeva BMS being discussed, but it is correct since the BMS "opens" those SSR outputs based on each cell voltage being monitored which is much better than total "pack voltage" as seen by both the charger and the Controller.
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Unread 09-13-2018, 02:08 PM   #64
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Default Re: Bit the bullet Leaf Lithium build

Yeah, there's really no standard, at least in the industry I retired from. The world I'm familiar with, anything 600 volts or less is considered low voltage. Above 600 is medium voltage, as it will reach out to greet you, though I've seen "Danger High Voltage" on panels with only 120 volts inside.

I'm also used to circuits being power, control, or signal, and even control and signal are often used interchangeably. Control and/or signal are either analog, discrete, or serial, though again, that's the world I lived in.

I don't have experience with RXVs.

For simplicity, I've always just referred to control as "wires" and power as "cables".
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Unread 09-13-2018, 02:40 PM   #65
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Default Re: Bit the bullet Leaf Lithium build

I would like to add a little more information to something that ag4ever mentioned in a previous post about the "brackets" for the gen 1 cells.

If You are using the 2013 leaf modules, You also have to be careful as there are 2 different kinds of modules in the entire Nissan leaf assembly.

If Your set has one or more of the modules that was originally used with the studded bracket, you either have to use the bracket (You can cut off the part with the studs) or use 0.056" washers in its place.

If you do not, the cells inside those modules will be over compressed when you torque the threaded bolts.

The picture below shows the 2 different module profiles used, notice the recessed area on the tin plate for the bracket on one of the modules:

Attached Images
File Type: jpg Leaf_module_differences_mounting_plate.jpg (164.8 KB, 0 views)
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Unread 09-13-2018, 04:26 PM   #66
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Default Re: Bit the bullet Leaf Lithium build

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Originally Posted by DaveTM View Post
Anyway......tell me more about the HBD41AB disconnect!!
You don't need the HBD41AB. This is a manual disconnect switch. I plan to install this switch right off my battery + (after the main fuse, but does not really matter) and use this as a "storage" battery disconnect. This is just my way of being lazy and not getting the tools out to manually remove wires if I plan to leave the cart at the hunting ranch for a prolonged period of time. I intend for all loads to be wired in after this switch so the entire cart will be dead with no parasitic losses when in the off position.

http://www.gigavac.com/sites/default...heet/HBD41.pdf



For $49 + some extra wire and connectors, it is cheap insurance, safety and convenience. This one is rated at 400 amp continuous and 2,000 amp for up to 1 minute. Also rated for 5,000 cycles (13 years if turned on/off everyday) at 24v.

Also, the last digit in the model number is a black switch handle, not red like in the image.
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Unread 09-13-2018, 04:30 PM   #67
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Default Re: Bit the bullet Leaf Lithium build

Quote:
Originally Posted by Sergio View Post
I would like to add a little more information to something that ag4ever mentioned in a previous post about the "brackets" for the gen 1 cells.

If You are using the 2013 leaf modules, You also have to be careful as there are 2 different kinds of modules in the entire Nissan leaf assembly.

If Your set has one or more of the modules that was originally used with the studded bracket, you either have to use the bracket (You can cut off the part with the studs) or use 0.056" washers in its place.

If you do not, the cells inside those modules will be over compressed when you torque the threaded bolts.

The picture below shows the 2 different module profiles used, notice the recessed area on the tin plate for the bracket on one of the modules:

Good to know since my modules that just arrived today came from a 2013. Neli did not indicate those might be needed when I asked about the gen 1 spacers.
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Unread 09-13-2018, 05:44 PM   #68
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Default Re: Bit the bullet Leaf Lithium build

Quote:
Originally Posted by ag4ever View Post
You don't need the HBD41AB. This is a manual disconnect switch. I plan to install this switch right off my battery + (after the main fuse, but does not really matter) and use this as a "storage" battery disconnect. This is just my way of being lazy and not getting the tools out to manually remove wires if I plan to leave the cart at the hunting ranch for a prolonged period of time. I intend for all loads to be wired in after this switch so the entire cart will be dead with no parasitic losses when in the off position.

http://www.gigavac.com/sites/default...heet/HBD41.pdf



For $49 + some extra wire and connectors, it is cheap insurance, safety and convenience. This one is rated at 400 amp continuous and 2,000 amp for up to 1 minute. Also rated for 5,000 cycles (13 years if turned on/off everyday) at 24v.

Also, the last digit in the model number is a black switch handle, not red like in the image.
I just installed a heavy socket/plug at the pack where the main power cables plug into it.
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Unread 09-13-2018, 07:39 PM   #69
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Default Re: Bit the bullet Leaf Lithium build

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Originally Posted by BobBoyce View Post
I just installed a heavy socket/plug at the pack where the main power cables plug into it.


Me too, big Anderson.
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Unread 09-13-2018, 08:14 PM   #70
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Default Re: Bit the bullet Leaf Lithium build

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Originally Posted by DaveTM View Post
Well, this morning I decided to focus on the battery pack and began to fully unpack 'em and clean up the styrofoam bits from packing. I turn the pack to it's side......only to find out the pack was damaged during shipping. The end module is obviously damaged......I haven't disassembled the whole pack yet to see if any other modules were in fact damaged. CRAP!!! I just sent an email to the seller to see what we can do about this.

After receiving my modules today, I would take the seller up on the offer to pay $20 to keep it. I seriously doubt any damage was done to the actual cells.

My cells were packed horizontal instead of vertical like yours, so the weight of 6 modules was pressing on the 7th there was a bit of bent casing, but not damage. All cells read within .009v of each other.

If I could buy some more at $20 each, I would jump on it. Probably try to make an extended run time quad from a couple modules. Or make a 14 module pack. Either way, $20 is a smoking deal.
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