[Driving] Freelander EV With Gen1 Leaf electrics and Original EVBMW VCU

[Alibro]

Since my last update there have been a couple of big changes but first some smaller stuff.
I've built up a frame to hold the electronics and maybe some batteries (if there's room) under the bonnet.

This arrived 10 days ago.

You may know if you've been following this build I've been dithering for months over how to resolve the charging/BMS/DC to DC conundrum.
I kept myself busy welding and grinding but had come to the point where I needed to make the decision so plumped for purchasing another two 4S modules and have a go at making the Nissan Leaf BMS and Charger work.
Only thing is the two modules came with a few friends.
Buying two modules was more than 1/4 the price of a full pack so made no sense.
This pack is the same age as my first one so the modules should be close enough mileage wise to be OK.
Having the two packs also means I have more options for packaging the modules, I can use more 4S or more 2S, whichever fits better.
I haven't decided whether to sell the extra modules or hang on to them for future projects but will worry about that later.

The other big update is this

It's a 2004 Freelander SE with all the usual SE options.
It was being sold as spares repairs because of a few minor issues but is running and driving so I'm hopeful this will be the one.

[Alibro]

Here is my latest video. Most of it was shot last summer but I only got round to editing and posting today.

[Alibro]

Work has been quiet recently so I've had time to edit the footage taken over the Summer and Autumn so here's another update.

[Alibro]

You'll have to decide if this is dumb or not.

[Alibro]

I finally put together a video about the BMS connections.
I had originally planned to wait until I had the charging working before putting this out but we're still not there yet.

[Alibro]

I eventually got round to editing and posting Video part two of the battery module BMS connections. In this video I'm making the BMS adapter cables for the eGolf Slave modules.
Unfortunately I still haven't managed to get charging working as it looks like the Nissan Leaf Gen1 onboard charger is controlled differently to the Gen2. I say that because I found a thread on the Nissan Leaf forum where an owner has been able to kick his Gen2 OBC into life but I have followed his instructions and mine is not working.
I've spent weeks on trying to get the OBC working but have decided to move on and will now concentrate on fitting the battery modules and getting the thing moving. The time wasn't completely wasted though as I've learned a lot about sending CAN messages and hopefully now have a reliable way of sending the CAN that will be needed later.

[m.art.y]

So have you got the Nissan Leaf BMS working with e-golf cells? Balancing and voltage reporting? Is there a way to monitor voltages with Leaf BMS?

[Alibro]

So have you got the Nissan Leaf BMS working with e-golf cells? Balancing and voltage reporting? Is there a way to monitor voltages with Leaf BMS?

Yes mate. It was really simple in the end.
I took the BMS CAN wires to an OBDII socket, plugged in a Bluetooth adapter and used LeafSpy.

[m.art.y]

Yes mate. It was really simple in the end.
I took the BMS CAN wires to an OBDII socket, plugged in a Bluetooth adapter and used LeafSpy.
Screenshot_20220502-001220.png

That's really cool! Do you know how Leaf balancing works? Is it all the time or only when charging? Can you choose which voltage to charge to?

[Alibro]

To be honest no, I don't know. it seems to be balancing the entire time it has 12V but the current is so low it is very very slow. I've taken the pack apart again as I want to get it installed in the car so can't do any more testing for a while.

[Alibro]

So it turns out multiple laptop chargers wired in series can be used to charge HV.

As a test I connected 6 x 4S modules to give 92V. I then connected 5 x 19.8V chargers in series to give 99V and after turning on the psu's connected them together.
This didn't go well as the chargers instantly shut down and refused to come back on until I disconnected them from the batteries.
I then connected a 12V 60W lamp in series and tried again and the result is below.
I'm seeing 3A and 92.3V at the batteries and 98V at the psu side of the lamp.
These are 6.9A psu's so are well within their comfort zone and the voltage is slowly rising at the batteries.

It's all a bit dodgy looking but as a proof of concept it works.

[Alibro]

Here is the latest video.



The footage was taken over a couple of months and some was lost so it's a bit disjointed but hopefully still interesting. As always on this build there were steps forward and steps back but getting the BMS working was a big thrill for me. It allows me to move forward knowing I can monitor all the cells.

[Alibro]

This is a sneak preview for Openinverter.Org as I haven't made it made public. I plan to use it as part of a longer video next week.
This was the first time I was able to drive the car using full power.
It is front wheel drive only here.
Everything was installed temporarily so I was holding back to make sure nothing bad happened, this was less than half throttle in 2nd gear.
Also I was using mostly just the hand brake as the vac pump is not installed yet.



Many thanks to Damien and Johannas for all their hard work that made getting this far possible.

[paaa]

Congrats on your progress

[Alibro]

Congrats on your progress

Thanks mate, another year or two and I might be finished.

[Bigpie]

Nice one, looks nice and lively

[Alibro]

Nice one, looks nice and lively

Thanks, it felt great, nice and smooth with plenty of go. I had to be careful as I don't have the vac for the brakes sorted yet.

[Bigpie]

Wish I could fit one of these motors in the Beetle

[Alibro]

Wish I could fit one of these motors in the Beetle

It isn't that much bigger than the rear Outlander motor.

[Bigpie]

Yea, the outlander rear won't fit either I've got the less deep front motor. Still trying to come up with what I'm going to do next.

[Alibro]

Yea, the outlander rear won't fit either I've got the less deep front motor. Still trying to come up with what I'm going to do next.

Make it a proper Beetle and put the motor in the back.

Seriously tho the Gen 1 Leaf motor and inverter along with the transmission would probably fit the back of your car. Might be a big job getting it through the DVA though.

[nkiernan]

Great to see it moving Alibro Fair play

[kev39]

Cracking Job, I never seen a Freelander move so fast.

[vwbrady]

congrats! that first drive feeling is pretty great! and somewhat motivating, if only for a moment.

[Alibro]

Great to see it moving Alibro Fair play

Cracking Job, I never seen a Freelander move so fast.

congrats! that first drive feeling is pretty great! and somewhat motivating, if only for a moment.

Thanks guys, it was a great feeling.