I thought the Leaf modules were each 4s, similar to how a 7.2v Prius module
is 6s. I stand corrected. They are 2s2p.

They can be modded to 4s according to
https://www.youtube.com/watch?v=kAznO_p_rEY

So, yes that does mean 228 amps at an 80 kW full throttle at 3.65 volts per
cell with 96 pairs in series.


On Sun, Aug 2, 2020, 02:13 Cor van de Water <cor.vandewa...@gmail.com>
wrote:

> Nonsense, the Leaf modules are internally parallelled, so every Leaf bus
> bar and interconnecting wire alread carries the full ~250 Amps peak current.
>
> Continuous power at highway speed is closer to about 20kW, so just over 50
> Amps.
>
> Internal resistance of the entire pack is about 0.1 Ohms.
> This includes the 96 series cell pairs, the bus bars inside the modules
> that connect the 4 cells together in 2s2p configuration, the 54 bus bars
> that connect the 48 modules, the fused service disconnect and from the
> contactors to the front plug, plus the 3 lengths of high voltage wire.
> Cor.
>
> On Sat, Aug 1, 2020, 8:35 PM Haudy Kazemi via EV <ev@lists.evdl.org>
> wrote:
>
>> I wouldn't recommend using the Nissan Leaf busbars in pack locations that
>> exceed 114 amps. The bars should be fine within the series strings, which
>> is what I meant in my prior reply. The ends of each of the 5 parallel sets
>> should be connected some other way.
>>
>> I have heard of copper pipe being crushed flat, then drilled, to create
>> suitable custom high amp busbars.
>>
>> On Sat, Aug 1, 2020, 21:35 Mr. Sharkey via EV <ev@lists.evdl.org> wrote:
>>
>> >  > stack several of them for the 5p17s pack
>> >
>> > While it looks like you have done the calculations on voltage drop
>> > and heat production, and the values are acceptable, I'd question the
>> > wisdom of trying to build a 5p pack using the Leaf busbars, mostly
>> > because layering up multiple short busbars to parallel the modules
>> > will result in a large number of junctions between the busbars,
>> > resulting in even more resistance and a lot of clutter on the terminals.
>> >
>> > When I built up the 2p5s pack for my Electrak this spring, I went to
>> > fleabay and bought some appropriately-sized copper stock, ran it
>> > through the drill press and made custom-fit busbars that could span
>> > four modules (paralleling two each and making the needed series
>> > connection between the paralleled modules).
>> >
>> > The only purpose for the stock Leaf busbars was to tie the middle
>> > terminals of the paralleled modules together. In my case, that was a
>> > good application, but if you are tying five center terminals
>> > together, I'd even make custom bars for that too, although they won't
>> > need to be very big, as in a perfect world, there isn't going to be
>> > very much current flowing in that part of the circuit.
>> >
>> > Photos of the Et conversion here: http://www.evalbum.com/79
>> >
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