Battery Bay Plan: Nissan Leaf Cells six group

SixGroup

This is my current CAD mockup of how I will package a group of six Nissan Leaf modules. I have 48 total modules from a Leaf battery, so I will have eight of them to distribute throughout my truck’s battery bays. I also have a CAD model of that:
batteryBays

Unfortunately, my existing Lead Acid (golf cart battery) bays are not tall enough to mount them vertically, so I am having to lay them sideways. This results in terminals being relatively close together in the two side bays. (I’ll probably slide a sheet of plastic between the two batteries after I get them installed to make it more difficult to drop a wrench down there and short things out. It’s only 32 volts total potential, but a lot of Amps!)

If you would like to know the specifications of a single module (and some people have asked) here is what I know:

From: http://www.electricvehiclewiki.com/?title=Battery_specs
Confirmed by Jay with a 2013 Nissan Leaf module.

lm_width=223; // mm – 8.7795 inches (measured 222 – 8.75 inches)
lm_length = 303; // mm – 11.9291 inches (measured 298.45 or 11.75 inches)
lm_thickness = 34; // mm – 1.3779 inches (measured 34- 1.3333 when compressed)
lm_weight = 3.8; // kGrams, or 8.3775 lbs

The power “bolt blocks” are 20×20 mm in size, and I modeled them around 1 inch in height. But, this height includes the space for a bolt head and a busbar on the top. In the CAD model I made them one inch tall, but in real life they are slightly shorter than that. The “bolt blocks” for the sense terminals in the middle are slightly smaller (18×18 mm) but the same height. So if you download my CAD model (link below) keep in mind that the top of the bolt blocks on the module includes a little extra wiggle room. The CAD software I use is OpenSCAD, which you can download for free. The file itself is human readable text.

BatteryPacks.scad (You may have to rename it from BatteryPacks.scad.txt to BatteryPacks.scad )

Building a battery from Leaf Modules – The Plan

I am in the process of replacing the twenty (20) six volt lead acid golf cart batteries that power my electric pickup truck with 48 Nissan Leaf battery modules. Because the battery bays in the truck are specificity designed to hold 20 golf cart batteries (and the Leaf modules have a different form factor), it’s not a straight-forward drop in replacement.

My initial design (not showing the compression plates that hold the six modules together in compression):
sixGroup
In the image above, the black bar is negative, Continue reading

UPC Barcelona Sodexo Unity cafeteria menus

The Sodexo “Unity” cafeteria at UPC in Barcelona offers a “complete menu” for 6.60 Euros that includes a starter, main, drink, bread and desert. You could typically choose between three different starters and main courses, mixing and matching.

The common vegetables were potatoes and artichokes. Ham, bacon and fish were the relatively common meats.

 

Below are photos of the ten meals I ate.

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Grilled fish, french fries, and kale.
Continue reading

How to recycle in Barcelona

Barcelona has many curbside recycling bins that are color coded.

barcelona_recycle_bins

The blue bins take paper, magazines & cardboard (folding boxes), but NOT the plasticized cardboard juice and milk boxes. (Which go into the yellow plastic bins instead. Also, no tinfoil, because it’s metal, not paper!)

blue_paper

The yellow bins take all types of plastic, including plasticized juice and milk boxes, but don’t throw in plastic toys or DVD/CD-ROM’s. They also take metal cans (I’m not sure if this is just aluminum cans, or all types of metal cans.)

yellow_plastic

The green bins take all types of glass, but no metal lids or lightbulbs, or ceramics.
green_glass

The brown bins are for organic remains (think compost), and all of your regular trash goes into the light gray bins. Currently very few people in Barcelona actually recycle, and most just throw all of their trash together into the gray bins.

How to open a 2013 Nissan Leaf battery pack and remove the modules

battery_open_front

I have opened my 2013 Nissan Leaf battery pack and removed the modules. The tools needed are:

  • 500 volt class 0 (or better) electrically insulated gloves
  • One or two full rolls of black electrical tape, for covering your tools and the terminals of the modules when you remove them.
  • Regular leather gloves
  • Side clippers and needle nose pliers for removing wire tiedowns
  • 1-1/2″ putty knife or chisel and hammer. (or preferably an air chisel)
  • 10 mm wrench (preferably a socket with ratchet)
  • 13 mm deep socket
  • 16 mm wrench and hammer (or impact driver w/ 16mm socket)
  • small flat bladed screwdriver for prying clips
  • # 1 Phillips screwdriver for removing screws on the sense terminal of the modules

You can watch the 13 minute youtube video here, or spend about the same amount of time wading through my wall of text below….

First: Remove the twelve 10mm bolts Continue reading

How to drop a Nissan Leaf battery pack (without an auto lift)

battery_pulled_out_from_under_leaf

NOTE: The battery pack has 400 volts inside of it. Be sure you know what you are doing and have the proper protective equipment, as it can kill you! It also weights 600lbs, so it can crush you!

I needed to remove the battery pack from my Salvage Nissan Leaf. The 2013-Nissan-LEAF-DG.pdf (Disassembly Guide) I found on the Nissan website has good instructions, but they assume you have an auto-lift (and custom battery moving system).

I didn’t want to purchase an auto lift, so I did it with the following tools on my concrete driveway.
tools_used

  • Class 0 – 500 volt electrically insulating gloves. Necessary when pulling the service disconnect, and the high voltage cables leading from the battery to the motor and interior cabin heater.
  • Continue reading

It’s Alive!

I was able to move the leaf under it’s own power (using two of it’s own wheels as well…) I titled the video “Drifting the rear end” because I want to see how many racing enthusiasts I can troll. This is probably the last time this Leaf will move under it’s own power, as the next step is to drop the high voltage battery pack.

Booting up a Nissan Leaf

Hojas, the wrecked 2013 Nissan Leaf that I purchased at an auto auction site was delivered to my house, and appeared completely dead. The first thing I did was to check the 12 volt “accessory” battery, and found that it had drained down to 1.5 volts. I think this was because in the collision one of the rear doors was knocked ajar, and the interior lights were illuminated because of that, but it could have also been due to the 2-3 months it had been sitting in the auction yard, or perhaps somebody initiated the emergency shutdown procedure.

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After charging the 12 volt battery back up, I was able to put it into “accessory” and “on” mode, Continue reading