2008 Nissan Quest Van with Tesla SDU. [FINISHED]

[Proton]

I started this conversion and made some progress.




For anybody interested in high voltage contractors, Battery hookup has some for $29.
TE Connectivity EV200AAANA 500a 0-900vdc Tyco 12/24v
https://batteryhookup.com/products/te-c ... a-0-900vdc

If anybody has info where in USA I can make some custom CV axles please let me know.
Next would be the CV axles and the OIL pump modification. did not want to do that but I guess I have no other option.

[Sector7e]

Nice. What made you decide on the Nissan Quest? I'm working in the initial planning phase of converting a 1996 Nissan D21 4x4, and will start a post in the next few weeks.

[Proton]

I had the Nissan Quest. I really want a Class A motor home or Mercedes sprinter but that is more expensive and complicated since they require more power. This car would be a waste of money if it would not be cheap. I want something that can be used for camping and living in it. for daily use we have 2 2010 Toyota Prius that do the job very well.

What I care is the motor inverter combination. I really do not care about Batteries because they will only get smaller.
Still researching a motor /inverter for a big car.
In the mean time this is a good way to learn.

[Sector7e]

I had the Nissan Quest. I really want a Class A motor home or Mercedes sprinter but that is more expensive and complicated since they require more power. This car would be a waste of money if it would not be cheap. I want something that can be used for camping and living in it. for daily use we have 2 2010 Toyota Prius that do the job very well.

What I care is the motor inverter combination. I really do not care about Batteries because they will only get smaller.
Still researching a motor /inverter for a big car.
In the mean time this is a good way to learn.

What is your range goal for this project? Are you planning on putting solar panels on the roof to utilize while camping?

[Proton]

I need at least 120 miles range.

On my house I have 3kW of solar panels and I ordered another 12 panels 5.76kW that are probably coming today. Trina-Solar-480W-252-Cell-Mono.

https://www.renvu.com/Trina-Solar-480W- ... olar-Panel

these are big: Module Length [in]: 91" x 40", so 231cm x 102cm. that will cover 85%- 90% of the van roof.
I have to find a way to connect the solar panel to the future battery. This is only 37V under load.
.48kw x 6hr = 2.88 kw a day which will add to the range. I will look to add 2 solar panels and expand them while parked. will see how heavy they are.

[Proton]

Approximate range I think I can get:


http://www.cascadiamotion.com/evbot

[Proton]

I am planning for now to use 160 AH LFP batteries at 358V that would be 57kW at max usable power.
Is anybody here with a completed car that can give me some numbers of how much they pull when accelerating or if 57 kW is enough for a good acceleration?

[Proton]

I played with the EVbot from cascadia motion. and it says that even if I limit the motor to 160Ah it's still 1 second faster than the original 3.5 liter motor and that with the Tesla 9.43:1 gear ratio.
if I would be able to change the gear ratio to 11:1 it would be 2 seconds faster with only 160Ah.

https://purperformance.com/p-29669-rpm-calculator.html

http://www.cascadiamotion.com/evbot

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[Proton]

Continuous power for Tesla SDU is only 35kW. 160 Ah x 358V = 57.2kW.

Now, the only problem would be Regen. I would not be able to regen 90Kw that Tesla SDU can do.

[Proton]

Just got the data sheet for the 160 AH batteries. they look good.

Pulse Charge/Discharge for 60 seconds at 2C. and normal charge .5C. normal discharge 1C. I can do easy 0 to 60

[Proton]

CV Axles:

the best price I found is at dutchmanaxles.com. they said $600 to $700 for 2. Next closest offer from driveshaftshop.com was $1600 + shipping.

https://dutchmanaxles.com/images/orderi ... ned_cv.pdf

Dutchman brothers need the following to fulfill the order.

Pretty much need to cut the Nissan axle and 1 Tesla axle and tac weld them at the required length and send it to them. they can make the Axle shafts only.
I like this idea a lot better because I can take the ends from Nissan and from Tesla and just plug them in. I can buy spares for Nissan and Tesla for the future.

[EV_Builder]

Yupsz; it's the best wat. Let them cut a new axle with both profiles from different cars on each end.

[Proton]

Did anybody tried to use a Hybrid inverter as a charger? it can take AC grid and DC from solar panels.


https://www.renvu.com/Growatt-MIN-7.6kW ... d-Inverter

Inverter Type: Hybrid inverter
Maximum/Peak Efficiency [%]: 98.5 < -------------------------------------------
CEC weighted efficiency @ 240V [%]: 98
Transformer / Transformerless: Transformerless
DC Power Rating [W]: 22800
Nom. DC Voltage [V]: 360 <--------------------------------------------
Max. Input Power [W]: 22800
Max. Input Voltage [V]: 600 <-------------------------------------
Max. Input Current [A]: 54
Min. DC voltage / start voltage [V]: 50 <-------------------------------------
Min. DC voltage / start voltage [V]: 50
Number of DC String Inputs (Inlets): 8
Number of MPP Trackers: 4
Max. Input Power per MPPT [W]: 5700
Max. Input Voltage per MPPT [V]: 600
Max. Input Current per MPPT [A]: 13.5
Voltage Lower Limit for MPP Range [V]: 50
Voltage Upper Limit for MPP Range [V]: 550
DC Disconnection Type: Integrated
Reverse-Polarity Protection: true
Ground-Fault Isolation Detection: Yes
AC Power Rating [W]: 11400
Nominal AC Power [W]: 11400
Max. AC Power [W]: 11400
AC voltage range [V]: 208V: 183-229V / 240V: 211-264V
AC grid frequency [Hz]: 60
Max. output current [A]: 48
Nominal AC Voltage [V]: 208/240
Maximum AC Voltage Range [V]: 264
Nominal AC Frequency [Hz], range [Hz-Hz]: 60
AC Connection Type: L1/L2/N/PE
AC Current Distortion [THD%]: <3%
AC Input Wire Gauge Range [AWG]: 6 AWG - 8 AWG
Sleep (Night) Consumption [W]: <5W
NEMA Enclosure Rating: NEMA4X (IP65)
Cooling Method: Natural Convection
Ambient Temperature Range [°C(°F)]: -25°C to +60°C (-13°F to +140°F)
Operating Humidity [%]: 0~95%
Operating Altitude [ft/m]: 9843ft (3000m)
Display: OLED
Communication: RS485 included, WiFi/4G Optional
Basic Warranty [Years]: 10
Warranty Extension Options [Years]: 15,20
Compliances: IEEE1547, CA Rule21, Rule14(HECO Compliant), FCC Part15 Class B, UL1741,UL1741SA,CSA C22.2, UL1699B, UL1741 CRD
AC grid range [Hz]: 45-65
Max. recommended PV power (@ module STC): 22800

[johu]

I am planning for now to use 160 AH LFP batteries at 358V that would be 57kW at max usable power.
Is anybody here with a completed car that can give me some numbers of how much they pull when accelerating or if 57 kW is enough for a good acceleration?

That's super conservative. The data sheet specifies 2C for 60s, just roll with that. You're not going to accelerate for 60s

Now, the only problem would be Regen. I would not be able to regen 90Kw that Tesla SDU can do.

Same here but you will find even 60 kW of regen is quite hefty.

[Proton]

I was looking at the batteries I am using in my solar system, and they are powerful. Unfortunately they are also heavy. In the video I am saying abut 200lb but actually they are 274kg. just 114w/kg.
I already used them in my solar system for 4 years.

[Proton]

Custom CV axle shafts are done.
Quick video

[Proton]

Is the angle, for CV Axle too much?

[EV_Builder]

Can you measure (calculate ) the angle? It's better to have factual numbers then gut feeling.

And if you want to use feeling...how does it feel (rotate) now anyway.
Did you tu to spin it? Vibrations?

[Proton]

I still have to mount the 2nd one. I didn't used the motor to spin it yet.

[Proton]

Because I destroyed the first CV from Nissan I bought a second one. Problem is that 2nd one is about 5-6 mm in longer. I could probably still use it, but just to be safe I ordered another one that seems to be the right size.

[Proton]

Initially I though that I have to use the Prius throttle I bought for testing, but now I discovered that the Nissan also has a throttle with wires. Problem is that I cannot find a diagram to show me which wires to use.
There is any way I can find out with multimeter which wires to use?

[johu]

I'm quite sure it'll need 2x 5V, 2x GND and outputs 2 somehow proportional position voltages.
Just a wild guess: pink and orange 5V, green ans white/black signals, black and white ground. Try with a very low current limit, like 20 mA

[Proton]

12v Battery - Amo box.
balancer is 4s not 16s as I said in the video.

[crasbe]

Initially I though that I have to use the Prius throttle I bought for testing, but now I discovered that the Nissan also has a throttle with wires. Problem is that I cannot find a diagram to show me which wires to use.
There is any way I can find out with multimeter which wires to use?
IMG_20230708_112054_462.jpg

The Service Manual includes a schematic, I found one online (without registration bullshit) for a 2016 model: https://procarmanuals.com/pdf-online-ni ... ce-manual/

As usual, the Nissan manual is quite outstanding, here are some screenshots, which are relevant for you:

(Page 1819)

(Page 1803)

(Page 2233)

If you want to, you can add this information (if it applies to your case) with the part number and wire colors to the OpenInverter Wiki: https://openinverter.org/wiki/Nissan_El ... ttle_Pedal (the page still has to be created)

I'm quite sure it'll need 2x 5V, 2x GND and outputs 2 somehow proportional position voltages.
Just a wild guess: pink and orange 5V, green ans white/black signals, black and white ground. Try with a very low current limit, like 20 mA

This is true for most throttle pedals, however I learned recently that the Volvo V70 II (with Bosch ME7? I think?) has a different setup: There is one analog output which is supplied with +5V from the ECM and there is a digital circuit with +12V supply from another circuit which outputs a PWM signal to the ECM and the ETM (Electronic Throttle Module). Later ones even have CAN I think.

I found that out because the throttle pedal shares a fuse with the magnet clutch of the AC compressor, and when the magnet clutch burnt out on my partner's Volvo, a weird Throttle Pedal error appeared at the same time
That was quite the rabbit hole of throttle pedals I went down and it took some time to make the connection

[Proton]

The Service Manual includes a schematic, I found one online ....

Much appreciated !!!

On mine it looks pins 4 and 8 are not used. So without those 2 pins we have 123567 which I am guessing are 123456
PIN 1 - Black
PIN 2 - White
PIN 3 - Green
PIN 5 - White/Black
PIN 6 - Orange
PIN 7 - Red/Blue

Or

PIN 1 - Black
PIN 2 - White
PIN 3 - Green
PIN 4 - White/Black
PIN 5 - Orange
PIN 6 - Red/Blue