Upgrading Fluence battery with cells of Leaf GEN2 24kw battery

Upgrading Fluence battery with cells of Leaf GEN2 24kw battery

terkaa
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Hi,

Because SOH% in our Fluence is at 69% (And because of personal interest) I decided to take a route of replacing cells with ones from GEN2 Leaf 24kw battery. I already bought Leaf battery pack with 98% SOH out of 2015 Leaf. Should Leaf cells be same physical size and swapping cells be quite straightforward?

Tero
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Re: Upgrading Fluence battery with cells of Leaf GEN2 24kw battery

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  • Andi42
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If you can send a photo of the cells I can tell you...
Fluence Z.E. seit 12/2015 | Corbin Sparrow seit 09/2011 | Kewet ElJet3 von 10/2005 - 02/2016 | Peugeot Scootelec

Re: Upgrading Fluence battery with cells of Leaf GEN2 24kw battery

terkaa
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Re: Upgrading Fluence battery with cells of Leaf GEN2 24kw battery

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  • Andi42
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Hi, they look very similar to the original Fluence cells but they are not identical.

I would expect the same issues that I had with the Leaf 30kWh cells:

- Different usage of the cooling mats
- Modification of the horizontal support bars
- Modification of the end-plates.

So, in the end, they will fit, but it's not a seamless replacement.

Cheers
Andreas
Fluence Z.E. seit 12/2015 | Corbin Sparrow seit 09/2011 | Kewet ElJet3 von 10/2005 - 02/2016 | Peugeot Scootelec

Re: Upgrading Fluence battery with cells of Leaf GEN2 24kw battery

terkaa
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Hi,

I will follow steps from guide you made, before I start my project. Btw how much range you have now with 30kw battery?

Tero

Re: Upgrading Fluence battery with cells of Leaf GEN2 24kw battery

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  • Andi42
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Hi Tero,

as I wrote in the modification thread I drove in summer 189km on a fully charged pack. That was 26kWh out of a 30kWh pack (SOH 102%). These values sound reasonable as the cells are only charged to 4.1V/cell in the Fluence.
For a healthy 24kWh pack you could expect getting about 20kWh.

Cheers
Andreas
Fluence Z.E. seit 12/2015 | Corbin Sparrow seit 09/2011 | Kewet ElJet3 von 10/2005 - 02/2016 | Peugeot Scootelec

Re: Upgrading Fluence battery with cells of Leaf GEN2 24kw battery

terkaa
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Re: Upgrading Fluence battery with cells of Leaf GEN2 24kw battery

terkaa
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It is done. And car still works :) Thank you very much Andi for great guide. Swap was similar to that you did. Only one minor difference was that cells with studs had bracket spot welded to other side so those had to be "flipped to get corret +-+-+- order for stacks. How soon should I expect SOH% to increase?

Tero

Re: Upgrading Fluence battery with cells of Leaf GEN2 24kw battery

Tandy0
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Amazing pictures buddy.

I think you need to reset the range by holding down one of the buttons on the wiper stalk until it resets.

Re: Upgrading Fluence battery with cells of Leaf GEN2 24kw battery

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  • Andi42
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Congratulations - well done :-)
ow soon should I expect SOH% to increase?
It will increase each time you charge. I did a full charge after I swapped and then dive the car until I was in turtle mode. Then I recharged.
But even without that you should see an increase every time you charge.

Cheers
Andreas
Fluence Z.E. seit 12/2015 | Corbin Sparrow seit 09/2011 | Kewet ElJet3 von 10/2005 - 02/2016 | Peugeot Scootelec
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