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UK Nissan e-NV200 / Leaf 14kw Powerwall 14s4p
#1
In January 2015 I got 12x Solar panels installed on my roof giving me 3.18kwh power using my SolarEdge inverter. After a few years of having solar, it has pained me to see how much energy that I don't use getting exported to the grid even though I have an Immersun Hot Water Heater and Zappi Car Charger soaking up lots of the excess power. I had been on the market for an off-the-shelf  battery solution like the LG Chem or Tesla Powerwall but had started harvesting 18650 cells with a though of maybe going down that route.

So about a year ago a friend of mine contacted me advising that an EV car shop had 28x 2011 Nissan e-NV200 Generation 1 batteries for sale which are the same batteries as the Nissan Leaf. I had watched a lot of videos on YouTube and discovered this website. After spending countless hours watching videos and reading other threads of leaf powerwall builders, I decided to take the plunge and traveled to the Republic of Ireland and picked up the batteries and brought them home. I was not expecting the 24x module pack to be so heavy. It was so heavy that 2 of us struggled to lift them out of the boot of my car. We just about managed to carry it from my car to the garage after some almighty swearing.



Now that we got the 28 modules home, it was time to start taking them apart. The photos show the stages I took in unbolting the packs. I stacked the modules up in preparation for assembly. I kept all the accessories that came from the pack as I wanted to reuse as much of the original hardware as possible.












My original plan and design for my pack has changed significantly since last year. I am going to document each stage on this thread knowing that these where not the best methods but just want to document my mistakes so that others coming after me do not make the same mistakes as I did.

My initial plans was to compress each 4 parallel modules between MDF wood


But after posting on another thread, I was advised by a number of other Powerwall builders that this was not safe. So it was back to the drawing board.
I was offered a second hand network cabinet but the shape did not suit.

I also had access to old medical cabinets but once again I choose against this idea



In the end I decided for a lockable smaller network cabinet. Perfect!
Oz18650, OffGridInTheCity, Korishan And 2 others like this post
Battery Capacity: 14kwh  = 28x 2011 Nissan eNV200/Leaf Gen1 Modules (14s4p) with Victron Multiplus II GX 48/3000 AC Coupled Inverter
Solar Capacity: 3.18kwh = 12x REC 265PE BLK Solar Panels with SolarEdge SE4000 Inverter
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#2
So now that I had found my cabinet, I discovered it was quite a weak structure and certainly could not hold the weight of the 28 modules without adding extra  support in the base of the cabinet. I used some wood offcuts and cut the pieces to pack out the base of the cabinet.






I used the original base plate of the smaller 4 module pack for my base. It had to be grinded down a few millimetres in order to get it to fit properly in the cabinet


Next I got a rubber mat and cut it to size to insulate the bottom of the cabinet.


I bolted the base plate on top of the rubber mat

and then added the M6 threaded bars to bolt the modules together.


The next stage of my build is the assembly of the modules inside the cabinet.
In order for the cells to be the right way around I had to stack the right hand stack upside down as you can see in the picture below





The last stack of 4 modules gave me a problem. Because of the orientation of the cells they where not matching cell polarity cell layout so I had to improvise and out 2 modules upside down to match up the polarity. I had to build a made shift plate to put in between the modules to allow for proper compression of the stack. It may look a little out of place, but it works.
ajw22 and rottenkiwi like this post
Battery Capacity: 14kwh  = 28x 2011 Nissan eNV200/Leaf Gen1 Modules (14s4p) with Victron Multiplus II GX 48/3000 AC Coupled Inverter
Solar Capacity: 3.18kwh = 12x REC 265PE BLK Solar Panels with SolarEdge SE4000 Inverter
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#3
I'm so jealous (I'm at 8000+ 18650 and too late for me).  Fantastic work/pics, thanks for sharing!    
Upside down a "little out of place"...    no problem as your cabinet door does not have a window - who will notice? Smile
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#4
My next stage of the project was to cut the copper busbars to size and drill the holes
The copper bars I used was Copper flat bars Grade 101 which was 1" wide (25.4mm) and 3/6" thick (4.76mm). I cut
I was advised this is overkill, but I would rather over spec everything than have to rebuild it again in the future.
Cutting the copper was a slow and tedious task using a jagsaw which is all I had to hand. I cut 21 bars to 125mm in length
Once the bars where all cut, drilled the holes which where spaced approx 32.5mm apart

Each hole had to deburred which I did by hand using a deburring tool
Once I had the first 3 bars drilled and deburred and bolted them onto the first parallel set of modules

I continued drilling and preparing the busbars for the remaining 6 parallel packs

It was my intention to cut small 60mm busbar lengths to attach each parallel pack up in series but I had not ordered enough copper originally.
It was then when I realised I had made another fatal mistake. The final 3 busbars for the top stack will not fit due to the additional makeshift plates added for compression purposes. This added an additional 5mm to the busbar requirements making these 3 busbars excess to requirement.
Unfortunately this meant that I had to place another order for copper. After some sleep I decided that instead of using small 60mm lengths of copper to connect each parallel pack in series, that instead to make the build neater, I should replace most of 125mm busbars with 260mm busbars as seen below

I then cut a busbar to 178mm and used it to connect the bottom stacks together in series


The final pack required 2x 130mm busbars and one 265mm busbar to connect the final parallel stack.

So it was at this stage when my Batrium Watchmon 4 and 7x Leafmons arrived (before I had attached my final 3 bus bars)

As you can imagine I could not wait to get them setup so I started to put on a few of the leafmons to work out their best location

I cut the final few busbars and drill their holes and get them attached up to the pack


I've went and got myself a couple of cool stickers for the front of the network cabinet to keep any unauthorised hands away from the battery

Next I setup the Watchmon 4 network connecting all the cables in series around the cells





Next stage was to install the shunt



So this is up to present day.
I have ordered a Victron Multiplus II GX 48v3000 Inverter and it is due to arrive in the coming days. As my battery is stored in a detached garage, I have decided to use the ZigBee adaptors for wireless communication from my main fuseboard which will have a ET112 Energy Meter installed.

OffGridInTheCity Wrote:I'm so jealous (I'm at 8000+ 18650 and too late for me).  Fantastic work/pics, thanks for sharing!    
Upside down a "little out of place"...    no problem as your cabinet door does not have a window - who will notice? Smile
I only had a few hundred 18650's harvested so it wasn't a big deal to move over to the Nissan cells.
Noone will see the batteries other than myself and anyone reading this thread so I don't care if they are upside down or not Cool
rottenkiwi, pau1phi11ips, ajw22 like this post
Battery Capacity: 14kwh  = 28x 2011 Nissan eNV200/Leaf Gen1 Modules (14s4p) with Victron Multiplus II GX 48/3000 AC Coupled Inverter
Solar Capacity: 3.18kwh = 12x REC 265PE BLK Solar Panels with SolarEdge SE4000 Inverter
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#5
That is awesome bud! looking forward to see how the project progresses
BigDav likes this post
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#6
Yeah, me too. I'm in the UK and this is pretty much exactly what I want to build. Looks awesome! Looking forward to more updates.
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#7
pau1phi11ips Wrote:Yeah, me too. I'm in the UK and this is pretty much exactly what I want to build. Looks awesome! Looking forward to more updates.
Have you got your batteries yet? Where did you source them?
My Victron Multiplus II GX inverter arrives on Thursday so updates coming soon
Battery Capacity: 14kwh  = 28x 2011 Nissan eNV200/Leaf Gen1 Modules (14s4p) with Victron Multiplus II GX 48/3000 AC Coupled Inverter
Solar Capacity: 3.18kwh = 12x REC 265PE BLK Solar Panels with SolarEdge SE4000 Inverter
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#8
(01-06-2020, 11:17 PM)BigDav Wrote: Have you got your batteries yet? Where did you source them?

No, not yet. Just been looking at listings on eBay. 7 Gen 2 modules for ~£500 or a complete 24kW 48 module pack for ~£3,200.

Where did you get yours?
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#9
pau1phi11ips Wrote:
BigDav Wrote:Have you got your batteries yet? Where did you source them?

No, not yet. Just been looking at listings on eBay. 7 Gen 2 modules for ~£500 or a complete 24kW 48 module pack for ~£3,200.

Where did you get yours?
I found mine on an Facebook ad for an electric car dealer in Kildare in Ireland. I paid €1200 for 28 Gen 1 modules

So my Multiplus II GX Inverter arrived today and I got stuck into the installation with the assistance of a qualified electrician for the consumer unit connection


Firstly the inverter was mounted to the wall.

We then installed the AC isolator and 32 amp breaker in the consumer unit and run 4mm twin and earth cable to the inverter. We also mounted the Mersen Fused Multibock on the wall and connected the ZigBee to USB converter for wireless communication to my ET112 energy meter

So then I crimped some M8 lugs onto 70mm copper cable and connected the positive and negative terminals from the battery to the inverter.


The electrican then connected the ET112 energy meter at my main consumer unit to monitor my energy usage and setup the ZigBee to RS485 converter. The ZigBees connected right away without the need to go through a pairing procedure which was nice.


After a few safety checks we where ready to switch on the inverter. It went straight into charge mode as we have not enabled the ESS mode yet.
The Victron firmware was then updated to version 2.42 and ESS mode enabled
We discovered a fault with the Victron very early in the process. The display was not working at all. After searching online unsucessfuly, I decided to remove the front panel of the inverter to see if the ribbon cable had become detached in transit and it had! I reconnected the ribbon cable and put the cover back on.
And that's me up to date for now. More updates coming soon...
Battery Capacity: 14kwh  = 28x 2011 Nissan eNV200/Leaf Gen1 Modules (14s4p) with Victron Multiplus II GX 48/3000 AC Coupled Inverter
Solar Capacity: 3.18kwh = 12x REC 265PE BLK Solar Panels with SolarEdge SE4000 Inverter
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#10
So I have been trying to get to understand how the Victron Multiplus-II GX should be configured for my application and I have hit a few problems.
The main concern is when I switch on the inverter it trips the RCD in the fuse box meaning that the garage is running in UPS mode with power supplied from the battery and not the grid. I cannot reset the RCD while the inverter is switched on. If the inverter is on CHARGER ONLY mode the RCD will not trip, although I cant work out how start charging?

Next problem is that I cannot register onto the VRM portal using my VRM ID which is still ongoing. I will update soon on this.

So when using the Batrium with my Victron, I am not sure if I need to use ESS mode or DVCC to allow the Batrium to be in control of voltages. More reading of the manuals required and any assistance would be much appreciated
Battery Capacity: 14kwh  = 28x 2011 Nissan eNV200/Leaf Gen1 Modules (14s4p) with Victron Multiplus II GX 48/3000 AC Coupled Inverter
Solar Capacity: 3.18kwh = 12x REC 265PE BLK Solar Panels with SolarEdge SE4000 Inverter
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