Dala's Leaf buildthread (2015 Nissan Leaf)

jdeadman

Well-known member
Joined
Mar 28, 2017
Messages
941
Wow That's a nice rate. Not sure what the coneversion to Canadian would be but we are currently paying 10.1c /Kwh due to Covid but normally we were paying Peak @ 20.8c /kWh Mid Peak @ 14.4c/kWh and Off Peak @ 10.1 c/kWh. We will see what they do on the pricing when this is all over
 

Dala

Active member
Joined
Feb 16, 2018
Messages
227
The final pieces of the stereo puzzle arrived! The fascia-plate and the reverse camera connector. Delivery time was 6months most likely due to the ongoing pandemic, but I wasn't in a rush with this :)

image_cqwenr.jpg


This is what the stereo looks like with the proper fascia plate surrounding it.

image_pniagc.jpg


And now I have a functioning reverse camera! The adapter supplied the 12V->6V converter that is needed to power the camera. It is HUGE when blown up on the 2DIN display, compared to the old radio which had a tiny screen for it. Just need to enable the reverse lines now in the software...

image_aozgam.jpg


Very satisfying to complete a side-project!
 

Dala

Active member
Joined
Feb 16, 2018
Messages
227
I still had an annoying rattle coming from the passenger door. Since I knew I had to open the interior again, I bought some STP soundproof mats. Since an EV doesn't emit any noise, creaks/drone/rattles are so much more annoying. I found the source of the creak, it was the sealing lip on the windows that rubbed the window frame. Once that was fixed I started with installing the sound deadening mats.

image_nuwkzj.jpg


I put two sheets in one door, cut them into smaller pieces to be able to cover the whole length of the door.

image_cpxkqd.jpg


And oh what a difference! When you close the door, it makes a more satisfying THUD instead of the factory THUNGGG noise. Now I just need to do 3 more doors :)
 

Dala

Active member
Joined
Feb 16, 2018
Messages
227
I got my new parking space all cleaned up over my vacation :) Overnight charging with 240V 8A is just on the edge what a 40kWh battery needs, so if I get the bigger 62kWh battery in the future I'm gonna have to upgrade the charger

 

Dala

Active member
Joined
Feb 16, 2018
Messages
227
Okay so this is something really cool. As some of you may already know the 24kWh pack in the LEAF doesn't actually let you use all those kWh. It keeps a buffer on top, and limits the charge voltage to 4.10->4.13V depending on model year. This means you get roughly 21kWh of usable capacity. But what if there was some way to unlock that buffer? Take a look at the attached picture ;)


image_nanzgg.jpg


That is precisely what I did on this customer car(and have already been doing on battery swapped cars). The difference here is that I ported this software, and made it specifically for non-upgraded LEAFs. I would love to share the code, but since I didn't write it by myself, I cant. But I can give you the gist of how it works.

So when charging is ongoing, the bridge starts to send cell-voltage requests, same thing that Leafspy would do. It keeps track of all the 96 voltage measurements, and makes sure no cell goes above 4200mV. The can-bridge hijacks the charge current requests that the battery is sending to the charger, and keeps requesting current. When battery is closing in on the desired voltage, the power is lowered gracefully until it hits 400W and charging is stopped by sending battery full messages.

Regarding safety, the engineering documents for the LMN02 cells specify 4222mV as maximum charge voltage, and the system will throw overvoltage codes if a cell goes above 4260-4400mV(depending on model) , so even long regen braking events with a fully charged car is unlikely to cause DTCs. Regen is heavily reduced with the battery this charged, so no worries there. Funfact, the on board charger in the LEAF acts like a lab power supply, and can deliver up to 440V!
 

daklein

New member
Joined
Sep 14, 2019
Messages
3
Very neat Dala!

A related suggestion: the bridge could adjust the charging rate dynamically, according to the available solar power available at the home. Don't want to import from grid, don't want to export, don't want to shut off solar when house battery is full, put that in the leaf. Some people have demand charges to avoid, so could reduce EV charge power when other house loads come on. Assuming the home automation systemprovides a desired EV charging power based on those goals. The home automation system could even pass on info from the utility, ie: peaking event active, slow the charging.

Instead ofamodified or fancy EVSE, make the leaf smart. Work regardless of which EVSE is in use. Thebridge would need some way to see what the currently available power is over WiFi from the home system. Maybe could do some trick with other devices that send can messages that the bridge can see (HVAC, etc), but the car is off. Or make something to modify the EVSE pilot signal received by the car. Or communicate over the bridge's 3rd can channel withOVMS. Hesitate to get into using complicated OVMS directly as the bridge, car turtles or worse if bridge is inop. Or use the serial port on the can bridge.

Could be a feature people would pay for, survey your customers?
 

gauss163

Member
Joined
Jun 28, 2020
Messages
284
Out of curiosity, what is the usage scenario that makes it worth suffering the typically big decrease in lifetime by charging it much closer to 100% SOC?
 

Dala

Active member
Joined
Feb 16, 2018
Messages
227
daklein said:
Very neat Dala!

A related suggestion: the bridge could adjust the charging rate dynamically, according to the available solar power available at the home. Don't want to import from grid, don't want to export, don't want to shut off solar when house battery is full, put that in the leaf. Some people have demand charges to avoid, so could reduce EV charge power when other house loads come on. Assuming the home automation system provides a desired EV charging power based on those goals. The home automation system could even pass on info from the utility, ie: peaking event active, slow the charging.

Instead of a modified or fancy EVSE, make the leaf smart. Work regardless of which EVSE is in use. The bridge would need some way to see what the currently available power is over WiFi from the home system. Maybe could do some trick with other devices that send can messages that the bridge can see (HVAC, etc), but the car is off. Or make something to modify the EVSE pilot signal received by the car. Or communicate over the bridge's 3rd can channel with OVMS. Hesitate to get into using complicated OVMS directly as the bridge, car turtles or worse if bridge is inop. Or use the serial port on the can bridge.

Could be a feature people would pay for, survey your customers?

Totally possible to do! But this is a really specific use case, and here up north where the sun only shines properly during the summer I don't think I'll have any customer base for a smarter Leaf charging. But I am going to be experimenting with reducing the charge rate, and maybe even making some brown-out load reduction functionality for the Leaf. But the bridge is fully open source, so with the next youtube video I release you will have all the knowledge needed to make such a firmware for the CAN-bridge :)

gauss163 said:
Out of curiosity, what is the usage scenario that makes it worth suffering the typically big decrease in lifetime by charging it much closer to 100% SOC?

So the early 24kWh packs seem to degrade no matter how much you take care of them. It seems like heat is the biggest killer. Charging closer to true 100% SOC is not going to degrade them much quicker, but if you are worried about degradation I also bundle the BatterySaver functionality with the capacity boost software, so you can set a custom chargestop% and e.g. only charge to 92% every day, and take it to 100% when you really need it. The capacity boost is for people that need more range right now, but ofcourse that won't be everyone.
 

Dala

Active member
Joined
Feb 16, 2018
Messages
227
Exciting news! I am opening up the ChargeCurrent repository to the public! The functionality has been confirmed working, here is an excerpt from my Patreon:

"The project started a few months when I was contacted about an issue. The problem was that a person had access to a workplace charging station, that was incorrectly sized off with a 110V 25A fuse (2.75kW absolute max). This led to the fuse tripping when a car was connected and tried to charge with 3.3kW. Maintenance couldn't do anything about it, other than reset the fuse. But we can solve this hardware issue with software! A CAN-bridge was installed onto the vehicle, and CurrentControl loaded onto it. The software was set to max allow 1.6kW via the onboard charger and the charger didn't trip! Quite the success!"

https://github.com/dalathegreat/Nissan-Leaf-ChargeCurrent
 

PaulKennett

Member
Joined
Oct 9, 2016
Messages
87
Korishan said:
Hahah, I like how you say they are exotic plugs :p That's what we use over here in the US.


image_efscnw.jpg


This one I think has one of the blades turned 90* to the other blade, correct? If so, this is standard for plugs here to designate they are 240V. However, it is strange that it specifically says 200VAC, not 220VAC or 240VAC. Most of our devices run between 210 - 240VAC that uses a full phase (we have split single-phase standard house installations. 3-phase is not common here)

Japan runs on 200VAC as their mains voltage - weird!
 

Dala

Active member
Joined
Feb 16, 2018
Messages
227
Today I went mobile. A customer needed help with a battery repair (HV contactor replacement). Here are some thoughts about acting as a mobile-tech. Due to the current ongoing pandemic, I packed lunch and lots of coffee, so I didn't have to shop anywhere. Oh, and hand sanitizer! The total roundtrip was 500km, so I had to stop two times for a quick zap. I successfully avoided people altogether! The entire deal was zero-waste, made with 100% renewable energy (Fortum C&D wind-power), and 100% vegan. I'm serious when it comes to sustainability :)


image_cglguj.jpg
 

Dala

Active member
Joined
Feb 16, 2018
Messages
227
So some updates of what I've been up to.

I bought a new LEAF! Or rather, my company bought an older Leaf. My current black -15 AZE0 only allowed me to develop the software so far, so I needed access to the older ZE0 Leaf. So I went and picked up Finlands cheapest one :) It's a white -12 ZE0, with the cold weather package. This will allow me to fix the remaining bugs in my software. You'll be seeing more of this car soon :)


image_tuhivp.jpg
 

Dala

Active member
Joined
Feb 16, 2018
Messages
227
Some more exciting stuff going on,

I recently released a Demo version of my upcoming software LeafEnhancer, to all my Patreon supporters.

image_vgqdar.jpg


The Demo version includes CapacityBoost(AZE0), BatterySaver & GlideInDrive. I'm gonna be making some youtube videos on the new GlideInDrive functionality soon :) More on this software later on, and if you're a Leaf owner and eager for more info, do check out the Patreon page ;)
 

Dala

Active member
Joined
Feb 16, 2018
Messages
227
So I've been coding up some new functionality for my Leaf. This is something I feel should have been mandatory on the Leaf from the beginning, since it makes for safer charging.


Now I can bring only my 3.3kW charger everywhere, and make adjustments when needed :)

I will be pushing this new feature to all BatteryUpgrade customers, and adding this to the LeafEnhancer package.
 

Dala

Active member
Joined
Feb 16, 2018
Messages
227
Alright, here is what I've been up to the past few days.

All this started since I needed a way to charge faster at the workshop garage, where I'm currently conducting all the actual work (battery upgrades, R&D etc.). I wanted to set up a proper charging station, and by proper I mean a safety first install. I already had an OpenEVSE unit that I was going to take into use, but I needed a way to mount a Type B GFCI (RCD/RCCB/RCBO, whatever you want to call it depending on where you live).


image_glewpe.jpg

"What is a Type B GFCI?" you might ask, so let's go over that first. A Ground Fault Circuit Interrupter, is a device that quickly cuts power in the event of a failure/short/touching conductor situation. This device cuts the power if 30mA of current starts to take a path that it shouldn't (like through a human body). In Finland, these devices started to be installed in houses during the 90s, and are now required by law in wet areas such as kitchens and bathrooms. You can read more on Wikipedia about this device: https://en.wikipedia.org/wiki/Residual-current_device . But what makes it special when it comes to charging EVs, is the Type B variant. Normally you only encounter Type A, which cuts power on sinusoidal residual current. Type B has additional protection, and can detect steady DC, and higher frequency current, or for combinations of alternating and direct current as may be found from single-phase or multi-phase rectifying circuits. Basically every waveform can be detected with the Type B one. Examples of where Type B should be used is EV charging stations, solar installs, frequency converters, medical devices, X-ray machines, escalators, welding gear and laboratoryequipment. This is set by standards EC 60364-7-722 och SS-EN 50178.

If a failure with over 6mA of DC leakage occurs, a normal type A GFCI will become blind! This is why it is so important to have this device. Some EVSEs outright lack the built in DC-protection, like the Tesla Wall Connector. http://www.gycom.com/docs/default-s...tblad_jordfelsbrytaretypb_lowres.pdf?sfvrsn=0

Now that we know why the GFCI device is so important, let's get to installing one! The workshop is located in a old building, timber construction from 1912. At some point during the 90s, the workshop got a renewed electrical system. Renewed is a strong word, since the more you look at it the worse it gets.

image_nsxkgg.jpg


The old fuse box uses ceramic porcelaine style fuses, and there is no easy way to add the GFCI. The old box has no waterproof (IPXX) ratings. It will be necessary to replace the whole fuse box with a more modern one.

image_irkgxr.jpg


So I contacted an electrician, and we went to town. No going back now!

image_wlweml.jpg


We settled on a Hager enclosure, and added some extra room at the bottom incase any upgrades will be needed in the future.

image_lvtnlj.jpg


Labelling all the wiring

image_lsvpol.jpg


The garage recieves three-phase 25A, which I'll definately be using more of in the future.The old unit was mounted directly onto the wooden walls, so we put some insulation behind the unit to make it even safer.

image_ucernk.jpg


Once it was all installed, all electrical outlets in the shop were also replaced with IP55 ones. It was so satisfying to see the completed unit.

image_yvbicz.jpg


Here is also the openEVSE powered on for the first time, quite the Fallout vibe :D

image_zykwdw.jpg


I really hoped you learned something here, and I am so pleased with having a safer installation at the shop. Now every outlet is protected, and there is less risk to use the electrical system.
 

Dala

Active member
Joined
Feb 16, 2018
Messages
227
OffGridInTheCity said:
If I'm understanding correctly - then standardDC Ground Fault protection, such as built-in to Midnite Classic controllers - are only Type A? (e.g. detect/protect against PV array short to ground from + DC). Re:https://www.midnitesolar.com/pdfs/DC Ground Fault Protectors explained.pdf
From the looks of it yes. Keep in mind that TypeB is a quite new thing, it was only in 2017 that it became mandatory on new installations, and until 2019 when people started to actually notice these on the market.

The spooky thing is that a 6mA DC leakage will disable Type A GFCIs, and even take out your neighbors protection!
Swedish video, but good infographic
 
Top