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Bilmerker => Tidlige elbiler: Think => Think City "Classic" (2000 - 2002 mod) => Emne startet av: PRensel på Lørdag 19. Mai 2018, klokken 08:21

Tittel: Think PIV4/Classic Leaf battery upgrade
Skrevet av: PRenselLørdag 19. Mai 2018, klokken 08:21
Hi,

I'd like to share my latest upgrade for the Think PIV4/Classic.
This is a full Nissan Leaf 24kWh batterypack custom build for the Think.
It fits in the original batterybox and attaches to the original wiring of the car.
The TIM/motorcontroller is modified so the motor has more power, 48kW instead of 20kW.

(http://www.diyelectriccar.com/forums/picture.php?albumid=865&pictureid=6449)

The original charger is replaced with two Brusa NLG chargers with a combined capacity of 6.6kW.

(http://www.diyelectriccar.com/forums/picture.php?albumid=865&pictureid=6457)

Because of the higher speeds the braking systems will be upgraded with ventilated disk brakes at the front and disk brakes at the rear. The suspension will be lowered and modfied by Intrax Racing suspension.



Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: elektroluxLørdag 19. Mai 2018, klokken 11:47
Looks good!

What voltage are you using? Will it be approved so you can sell car back to Norway?
Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: PRenselſøndag 20. Mai 2018, klokken 10:07
The Leaf modules are paralleled in 48S so the total system voltage is 196V. The packs max current is at least 600A but the Simotion inverter is limited to 280A, max motor power is 55kW.
The original DC/DC is reused as is the ContactorBox internals meaning everything works as original like pre-charge and pre-heating. The used BMS is a combination of Zeva BMS modules and some purpose build controllers. 

Underneath the modules there is a 25mm isolation plate and on top there is the room for the additional isolation. This could also replaced with an active water/glycol coolant/heating system if needed.

Theres no need for approval or retesting for use in The Netherlands, not sure how it works in Norway.

Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: elektroluxſøndag 20. Mai 2018, klokken 11:29
In Norway any change of battery chemistry means car needs new approval. The government have made the requirements that needs to be fulfilled so complex that they hope this will deter any enthusiasts from even tempting to get his car approved.

Strange as this means most simply convert illegally and there is no control on safety being followed. 

Luckily we have Caspar who is confronting the regulators and is determined to get his A266 with e-Up battery through the system.

I use other methods, and prefered is export/approval/reimport, but that means knowing the right people in EU who can help.
Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: OneMoreſøndag 20. Mai 2018, klokken 16:19
I have met very positive point of view from Norwegian government.
This I have stated many places. But non have wanted to go this road.
Simply since non want to invest the time and money.

It's wrong to only blame the government.


In Norway any change of battery chemistry means car needs new approval. The government have made the requirements that needs to be fulfilled so complex that they hope this will deter any enthusiasts from even tempting to get his car approved.
Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: CasparOnsdag 23. Mai 2018, klokken 22:48
Nice work, Im i progress of doing the same with battery modules from VW Eup. Are you using the main reley box from the Think? And have you had any problems with the pre charge, caused by higher voltage?
Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: PRenselTorsdag 24. Mai 2018, klokken 10:20
Hi Caspar,

Yes I have used the internals like PCB and relays from the CB (contactorbox)
The precharge is still work in progress but i might have an easy solution :-)
At this time it works but sometimes not on the first key-on sequence.
Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: PRenselMandag 11. Juni 2018, klokken 17:19
Enabled charging inlet for Mennekes typ2 mode3 charging.
Currently running with two Brusa NLG5 chargers for 6.5kW charging.


Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: elektroluxMandag 11. Juni 2018, klokken 20:22
 :+1:
Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: CasparMandag 11. Juni 2018, klokken 20:51
I have the same solution on both the Mini and the «VW» Think. Have you aded a resistor and a diode so you can use a normal wall box?
Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: PRenselTirsdag 12. Juni 2018, klokken 17:42
I have the same solution on both the Mini and the «VW» Think. Have you aded a resistor and a diode so you can use a normal wall box?

I have added a diode and two resistors (2k7 and 1k3) connected in parallel with a switch so i can toggle between mode3 'connected' and 'charge' state if needed. Unfortunally the ControlPilot signal of the Brusa chargers i have doesnt seem to be compliant with new EVSE's so i cant use that signal when charging automatically and the charger doesnt follow the EVSE's current limit.

I'm now working on modifying a Tesla Gen2 11kW charger which will be installed instead of the
Brusa's and will solve the CP 'problem'.


 
Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: efſøndag 17. Juni 2018, klokken 18:54
Forslag
Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: BauDemoFredag 31. August 2018, klokken 14:32
Enabled charging inlet for Mennekes typ2 mode3 charging.
Currently running with two Brusa NLG5 chargers for 6.5kW charging.

This is very nice cut for the inlet. Would you mind sharing how you did it and what would you do differently if you were to make it again?
Also can you post images on how it looks when closed?
I have collected couple of photos showing different alternatives for a chademo inlet here:
https://www.evmonitor.info/2017/02/possible-placement-of-chademo-inlet-on.html (https://www.evmonitor.info/2017/02/possible-placement-of-chademo-inlet-on.html)

Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: PRenselFredag 31. August 2018, klokken 18:27
This is actually the standard cut on the USA/export versions of the Think.
Some models in NO have the grey-silver cover but this one had the original USA door.
Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: odd fagertveitLørdag 03. November 2018, klokken 12:03
I like to use this in a boat, can you make this oppgrade for me. All el in the boat are from think classic
Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: elektroluxLørdag 03. November 2018, klokken 17:06
Why not use dedicated boat connector like this from Ratio :

https://www.ratio.nl/nl/catalog/marine/inlets/inlets/groups/g+c+a+view
Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: rzeponFredag 15. Mai 2020, klokken 21:26
Hi

My Think has 93000km age and he want's doing more :-) but battery said passs
.
What you know about conversion to lithium?
I have 10kWh packet from golf GTE and want use this in my Think, it possible
to change charge ending voltage in orginal charger and BMS? (my packet 48S2P
samsung sdi 2x28Ah)
When I install this battery Think didn't start :-(
start again on 36S2P, what should be do for instalation 48S2P?
Any sugestion

Chris
Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: BauDemoLørdag 16. Mai 2020, klokken 15:15
I have not done this myself, but I think you need to configure the simovert motor controller via siadis program (you would even need a pin?) to think that the high voltage in the battery is ok.
Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: rzeponTorsdag 21. Mai 2020, klokken 11:19
look at
https://www.reho.nl/phpBB3/viewtopic.php?t=6

Inverter its'locked
Tittel: Sv: Think PIV4/Classic Leaf battery upgrade
Skrevet av: BauDemoOnsdag 27. Mai 2020, klokken 12:53
I have heard that it is not that hard to unlock it...