Leaf Module Capacity Testing

I have been testing for capacity on my Leaf Modules I purchased. I built a charge and discharge setup and charged three modules to 8.2 volts and then terminated the charge. No CV holding until the amperage dropped. Just to 8.2 volts which is 4.1 volts per side of the module. The discharge results were pretty dismal and I was getting rather angry that I got cells that were damaged or old. All three netted the same results so I know my setup was good. However I did not charge all the way to 8.4 volts and hold to c/10. But in order to do that I would need to do a split charge on the module utilizing the center post. So I did a setup for each half with my PowerLab 8 and used my first module that only got 43ah out of it the first time. The charge was at 30 amps and I got 57.3 ah out of one side and 58.3 out of the other side using the power lab. I was even able to graph the volts and AH. It was great. Some places tested modules and only got 58 ah out of new modules. I also heard of some getting 60 ah out. But for used cells these modules did great using the split pack method and charging to 8.4 volts. As you can see on the voltage graph the beginning of the upward curve starts just before 4.2 volts. I could more than likely go to 4.3 volts with no issues. But I will stick with 4.2. More testing coming with different modules. The first graph is a goof up because I set my power lab wrong and it terminated at 3.6 volts. The first two graphs go along with the second two graphs. Combine them. One for voltage and the other for amperage. The last two were the second half of the module and I got it right and only needed two graphs. Volts and Ah. So you can see a real nice charge curve not unlike the LiFePO4 cells. So for the first go around it looks pretty good for these modules. Im a happy camper at this point. This will give my Bus some great range at cruise speeds of 55mph. Might be able to make it to Sac and back without charging. That would be totally cool.

More Box

Another Kudos to Rusher Electric Vehicles for the work done on the battery boxes for the Roadster. Lookin good. Once done I will remove the boxes and prime and paint all bare metal then I will use undercoating to cover the interior of the Bug. I will do the whole interior floor and back area to help shed water if it happens to get wet. So we should soon have a 60 cell 196 volt 900amp system for the little light weight roadster. I will look into getting some coco black/red mats for the Bug. Should look good. Match the red exterior. At some point I will have the Roadster painted. It will be red but not sure if it will be Ferrari Red or some other Red but it will be Red.

This box will keep the weight forward of the rear wheels and most of the weight as low as possible. Good for handling and weight balance. We will weigh the vehicle front and rear once done after the batteries are mounted.

More Box Photos

Rusher Electric Vehicles is now working on the rear boxes for the Roadster. This means things will be moving along rather briskly and I am cleaning up things for mounting into the vehicle. The current configuration actually allows for 70 cells total and I would only need space for two more which we can do later if I decide to put the AC-35 into the Roadster. Its still possible I do that and just use the DC system for the Bus with a Leaf Pack. It would allow for higher voltages but running a brushed motor for extended periods of time is not always the best thing to do.

Battery Box Update

Well the front battery box is almost done. I can't make the upcoming EVCCON but wished I could. I also picked up 48 Leaf Modules. Those suckers are right and left so you need to know about that before you stack your modules for fitting in a pack. I am in the process of checking them all but so far most are right on the voltage expected. They are used from wrecked vehicles but still quite usable. It was the only way I could afford these type cells. The Roadster will have a total of 60 CALB SE 100ah cells for a total of 192 volt system. The roadster did pretty darn good at 102 volts. Can't wait till I have it back on the road with full voltage.

The side little box that has a hinged top is going to be used for some components. There is not room for any cells in that box. The top of the box is removable and holds the cells in place in case of roll over.