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Old 02-07-2017, 11:15 PM
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WolfTronix WolfTronix is offline
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Default Leaf module based 150V 65Ah battery pack...

This post might be useful for those looking to upgrade lead acid based 144V systems...

Here is the configuration I came up with, while reusing the Nissan Leaf interconnects, safety covers, and BMS wiring.



This is one of four 150V 65Ah modules for my Solectria E10.

Total battery weight will be 656 pounds for a 150V 260Ah battery pack.
Under 700 pounds with all the module carrier plates, interconnects and BMS wiring.

I expect to get around 120 mile range when done (80-20 charge/discharge).

All the pics are here:
http://www.wolftronix.com/E10_LithiumUpgrade/index.htm

Video playlist is here:
https://www.youtube.com/playlist?lis...c3in4qWGy6dpfp

Enjoy,
Wolf
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Old 02-08-2017, 04:59 AM
Weisheimer Weisheimer is offline
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Default Re: Leaf module based 150V 65Ah battery pack...

That is one impressive feat there Wolf...

And you have temperature monitoring and battery monitoring by your upgrade of the original battery monitor system.

Nice work!
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Old 02-08-2017, 08:44 AM
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WolfTronix WolfTronix is offline
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Default Re: Leaf module based 150V 65Ah battery pack...

Yup, I replaced the Nissan's microcontroller with my own:



Now I have full control over the BMS hardware:
Cell Voltages.
Cell Balancers.
Current Sense.
Total stack voltage.
12V Auxiliary battery voltage.
I/O for the heaters.
CAN bus.
Temp Sensors.
Isolation monitor.
High Voltage Interlock.
EEPROM.
Miscellaneous I/O (Ignition switch, Watch dog timer, etc...).

Trying to have the Truck back on the road before Spring.
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Old 02-08-2017, 11:57 AM
CKidder CKidder is offline
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Default Re: Leaf module based 150V 65Ah battery pack...

Building an adapter board and putting your own CPU on there as basically the only hardware modification is pretty neat. That's slick stuff. Congrats!
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Old 02-09-2017, 10:02 AM
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Yabert Yabert is offline
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Default Re: Leaf module based 150V 65Ah battery pack...

Quote:
Originally Posted by WolfTronix View Post
Yup, I replaced the Nissan's microcontroller with my own
Wooo! Nice!
Good job.
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Old 02-09-2017, 10:17 AM
electro wrks electro wrks is offline
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Default Re: Leaf module based 150V 65Ah battery pack...

Great work! Would it be possible to do something like this with Tesla BMS hardware? I haven't checked in a while. Maybe someone else has already done it.
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Old 02-09-2017, 11:16 AM
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WolfTronix WolfTronix is offline
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Default Re: Leaf module based 150V 65Ah battery pack...

Quote:
Originally Posted by electro wrks View Post
Great work! Would it be possible to do something like this with Tesla BMS hardware? I haven't checked in a while. Maybe someone else has already done it.
I would assume so...

This is typically what I do when I can't extract the firmware and decompile into something I am familiar with to make the changes I need...

In this case, I reverse engineered the hardware of the LEAF BMS, and once I new what pins on the micro controlled what.

I was able to make my own interposer board that routs the digital and analog pins over to the digital and analog pins on my micro.

The only reason I have to make changes, is because I am not using all 48 modules in the Leaf battery pack, (I am only using 40 of them).

This makes the microcontroller unhappy, and spends most of its time throwing fault codes and repeatably looking for the missing monitor/balance chips. And it disables balancing of the cells, since cells are literally missing.

Also, any unpowered monitor/balance chips breaks the serial LIN communications bus, and you get no cell voltages.

Anyway, yes, I would assume someone could do exactly the same thing with the Tesla BMS.
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