Re: [EVDL] Leaf Busbar Ampacity

2020-08-02 Thread Lee Hart via EV
Mr. Sharkey via EV wrote: Beware! Copper water pipe is not pure copper, but is composed of alloy, you won't be getting the conductivity of 99% copper. Also, crushing and drilling pipe is time consuming and messy, the drilled holes can't be properly deburred, and the possibility of

Re: [EVDL] Leaf Busbar Ampacity

2020-08-02 Thread Haudy Kazemi via EV
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

Re: [EVDL] Leaf Busbar Ampacity

2020-08-02 Thread Mr. Sharkey via EV
> I have heard of copper pipe being crushed flat, then drilled, to > create suitable custom high amp busbars Beware! Copper water pipe is not pure copper, but is composed of alloy, you won't be getting the conductivity of 99% copper. Also, crushing and drilling pipe is time consuming and

Re: [EVDL] Leaf Busbar Ampacity

2020-08-02 Thread Jay Summet via EV
On 8/2/20 12:46 AM, John Lussmyer via EV wrote: This is for a Chevy S10. (converted some years ago using Lead-acid, we are updating it) I THINK we can fit 85 Modules in the battery boxes, which should significantly improve range over the old Golf Cart batteries. This truck has a Z1K

Re: [EVDL] Leaf Busbar Ampacity

2020-08-02 Thread Jay Summet via EV
The leaf pack is fused with a 200 (or is it 225?) amp mid-pack fuse, so I'd say they are rated at around 200 amps + safety factor... I used some (totally overkill) 1" wide by 1/4" thick copper bar stock when making my interconnects. I was sizing for a 500 amp max draw using 3 parallel leaf

Re: [EVDL] Leaf Busbar Ampacity

2020-08-02 Thread Jay Summet via EV
On 8/1/20 10:34 PM, Mr. Sharkey via EV wrote: 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

Re: [EVDL] Leaf Busbar Ampacity

2020-08-02 Thread Cor van de Water via EV
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

Re: [EVDL] Leaf Busbar Ampacity

2020-08-01 Thread Haudy Kazemi via EV
On Sat, Aug 1, 2020, 23:46 John Lussmyer via EV wrote: > Comments on multiple postings... > > On Sat Aug 01 20:34:51 PDT 2020 ev@lists.evdl.org said: > >I wouldn't recommend using the Nissan Leaf busbars in pack locations that > >exceed 114 amps. The bars should be fine within the series

Re: [EVDL] Leaf Busbar Ampacity

2020-08-01 Thread John Lussmyer via EV
Comments on multiple postings... On Sat Aug 01 20:34:51 PDT 2020 ev@lists.evdl.org said: >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

Re: [EVDL] Leaf Busbar Ampacity

2020-08-01 Thread Haudy Kazemi via EV
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

Re: [EVDL] Leaf Busbar Ampacity

2020-08-01 Thread Haudy Kazemi via EV
Gen 1 Leaf is rated at 80 kW. Pack is 96s2p. Leaf modules have 4 cells in each (48 modules x 4 cells each=192). Voltage is 96x 3.65 V=350.4 V 80 kW / 350.4 V = 228.3 amps 228.3 amps / 2 parallel strings = 114 amps per string NEC ampacity (conservative) rating for 1 gauge wire is 110 amps with

Re: [EVDL] Leaf Busbar Ampacity

2020-08-01 Thread Mr. Sharkey via EV
> 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

[EVDL] Leaf Busbar Ampacity

2020-08-01 Thread John Lussmyer via EV
I'm trying to figure out what the constant and 30-second Amp ratings are for some Leaf Busbars. The ones I have measure 0.78" wide by 0.08" thick. That calculates out to 40.25 mm2 (yeah, changing units) 1 awg wire is 42 mm2. BUT the busbar isn't insulated, and has a much larger surface area, so