Renault Zoe Battery Pack

The Renault Zoe used three variants of Battery

• Ph1 Zoe - 22kWh
• Ph1 Zoe - 41kWh
• Ph2 Zoe - 52kWh (Including a software locked to 41kWh variant)

All three variants use 2p96s configuration, for 360v nominal.

22 & 41kWh variants either came with 22kW AC charging, or 43kW AC charging (Q90/Q210 motor) using a system Renault names the Chameleon Charger, presumably due to the ability to operate over a wide range of charge current, and on either single or three phase power. This system also uses the motor stator winding as an inductor.

The BMS's, regardless of motor variant are designed with 43kW maximum charge rate in mind, and the most the BMS will ever show as "Input Possible" is 43kW. Interestingly this was never possible, due to the losses in on board AC-DC conversion (~10%).

52kWh variants either came with 22kW AC charging alone, or alongside CCS charging.

Phase 1 22kWh Battery Pack

2012 - 2016 Manufactured by LGChem

Phase 1 41kWh Battery Pack

2016 - 2019 Manufactured by LGChem, same dimensions as the 22kWh pack and a straightforward bolt-in swap to earlier cars.

The vehicle includes a plastic housing situated behind the battery pack incorporating a blower fan, and air-conditioning evaporator.

Cooling & Heating

On the 41kWh pack it includes two PTC heaters, one supplied by a 40amp fuse, and a second supplied by a 70amp fuse, theoretically allowing over 1kW of heating. These are relay controlled by the EVC.

The battery blower is controlled by the Air Conditioning Control Unit. It appears to be wired as a second interior blower (as in dual zone) heating system would be in other Renault vehicles, it has PWM control and a RPM feedback signal.

The Air Conditioning appears to only be used when the vehicle is charging and the battery temperature exceeds a setpoint.

The blower is activated in conjunction with the Air-Con or on its own. It is run when battery heating is in operation.

Construction

The battery pack consists of an aluminium alloy base to which the battery modules are mounted. There is a pressed steel lid that bolts on top of the base with a large amount of small bolts. A gasket is integrated into the base and can be reused. The many bolts appear to be scewing in to rivnuts which can be problematic if cross threaded or over-tightened, Renault have a procedure listed for replacing these.

Phase 2 52kWh Battery Pack

2019 - 2024 (end of Zoe production) similar dimensions to the previous two batteries, but with an additional 4 mounting bolts, and bolts directly to the chassis as opposed to via metal brackets. Can be bolted into original Zoe chassis if you add a plate with two captive nuts inside the chassis rail. Totally different pin configuration on the low voltage connector, and totally different CAN messages so requires a CAN translator. High Voltage connector is the same as the earlier models, wired the same.

Construction

The battery pack is largely the same as the previous models and consists of an aluminium alloy base to which the battery modules are mounted. There is a pressed steel lid that bolts on top of the base with a large amount of small bolts. A gasket is integrated into the base and can be reused.

Comparison

Technical Data	22kWh	41kWh	52kWh
Voltage	345.6v	345.6v	345.6v
Voltage Range
Number of Cells	192 (2p69s)	192 (2p69s)	192 (2p69s)
Discharge Power Short Term
Max Charge Power	43kW	43kW	??
Listed Capacity (on sticker on top of battery casing)	25920Wh	41000Wh	52000Wh
Usable Capacity	22kWh	41kWh	52kWh
Weight	280kg	305kg	326kg
Case Construction	Aluminium Alloy Base, Pressed Steel Top	Aluminium Alloy Base, Pressed Steel Top	Aluminium Alloy Base, Pressed Steel Top
Cooling Method	Blown AC Chilled Air from external evaporator	Blown AC Chilled Air from external evaporator	Blown AC Chilled Air from external evaporator
Heating Method	(in cold climate only) Blown Air from PTC	Blown Air from external 12v PTC	Blown Air from external 12v PTC

BMS Phase 1 (22kWh & 41kWh Packs)

Connector:

Part: Yazaki 7283-8854-30 (Harness Side), 7282-8854-30 (Battery side, although battery one is a bulkhead variant).

Pin	Function	Wire Size	Note
1	Permanent 12v	0.5mm2	Supplied by 5amp Fuse. Red Wire
2	N/C
3	Chassis Ground	0.75mm2	Black wire car side.
4	Chassis Ground	0.75mm2	Black wire car side.
5	Chassis Ground	0.75mm2	Black wire car side.
6	CAN High	0.5mm2	Green wire car side.
7	Switched 12v	0.75mm2	Green wire car side. Also referred to as "Emergency Cut-Off"
8	Main Contactor	0.5mm2	Green wire car side. Ground connection. Positive fed via Pin7.
9	N/C
10	Pre-charge Contactor	0.5mm2	White wire car side. Ground connection. Positive fed via Pin7.
11	N/C
12	CAN Low	0.5mm2	Grey wire car side.

BMS Phase 2 (52kWh Packs)

There is a version of the Phase2 Zoe that was sold with a battery that was software restricted to 41kWh, despite being a 52kWh battery.

Connector:

Part: Yazaki 7283-8854-30 (Harness Side), 7282-8854-30 (Battery side, although battery one is a bulkhead variant).

Pin	Function	Note
1	Permanent 12v+	Red wire car side.
2	Secondary CAN High*	*May not be present.
3	Main Contactor	Blue wire car side.
4	N/C
5	CAN High	Green wire car side.
6	N/C
7	Switched +12v	Green wire car side.
8	Secondary CAN Low*	*May not be present.
9	N/C
10	Pre-charge Contactor	White wire car side.
11	CAN Low	Grey wire car side.
12	Chassis Ground	Black wire car side.

High Voltage Connector (Same on all packs)

On the ZE40 Zoe, Renault list the cable size as 40mm2, although 35mm2 crimps fit.