A123 AMP20M1HD-A Battery pack kit

[cassschr1]

how long do the tabs need to be to work with these boards? Will 5/8 inch work?

[The Mighty Volt]

Sorry, I may have missed this, but how much are these units, say, for 24s? Thanks.

[agniusm]

the tabs has to be roughly 8mm long from teflon insulation even 7mm should do.
Estimated price for 24S kit is 136.85USD +shipping and 1$packaging.
Cheers

You can check shipping cost here: http://www.post.lt There is english version button top right corner.
Check the conversion rates here: https://ib.swedbank.lt/private/d2d/payments/rates/currency

[gensem]

Agniusm could you make 7s modules?

I know it sounds like an odd number but im thinking about using 28s A123 wich would end up being 100.8v (same as 24s lipo)

I would also like to know the dimension of a mounted 7s battery kit.

Thanks

[The Mighty Volt]

the tabs has to be roughly 8mm long from teflon insulation even 7mm should do.
Estimated price for 24S kit is 136.85USD +shipping and 1$packaging.
Cheers

You can check shipping cost here: http://www.post.lt There is english version button top right corner.
Check the conversion rates here: https://ib.swedbank.lt/private/d2d/payments/rates/currency

Thank you agniusm , you are very fair.

[agniusm]

Agniusm could you make 7s modules?

I know it sounds like an odd number but im thinking about using 28s A123 wich would end up being 100.8v (same as 24s lipo)

I would also like to know the dimension of a mounted 7s battery kit.

Thanks

Well 28S you can get combining 24S kit with 4S kit. At the moment i am stuck with block fabricators. No one seems to want to make them. A full headache..

[deVries]

I was looking to calculate exactly but it is too complicated. I guess if 20x6.3mm (126mm^2) copper bar is good for 320amps, if i would use 6mm round bar, meaning A=pi r^2=28.26mm^2, i would think that it would be good for 40amps brass or 70amps copper. I might be wrong but then again i am looking more at the clamping of the cells in to the pack and Builder should decide which way to terminate the pack. It is just not viable to design something to individual needs. I need to check current draw in my setup, and i use 14AWG on terminals, BMS and controller are rated at 30A.

These are continuous loads (see above).

What about peak amps & for about how many seconds? Just for estimate purposes.

[gensem]

Well 28S you can get combining 24S kit with 4S kit. At the moment i am stuck with block fabricators. No one seems to want to make them. A full headache..

I see... but I would still like the 7s blocks, so I charge using a regular rc charger and use either 21s or 28s depending on my hub motor kv and controller mosfets.

[agniusm]

I was looking to calculate exactly but it is too complicated. I guess if 20x6.3mm (126mm^2) copper bar is good for 320amps, if i would use 6mm round bar, meaning A=pi r^2=28.26mm^2, i would think that it would be good for 40amps brass or 70amps copper. I might be wrong but then again i am looking more at the clamping of the cells in to the pack and Builder should decide which way to terminate the pack. It is just not viable to design something to individual needs. I need to check current draw in my setup, and i use 14AWG on terminals, BMS and controller are rated at 30A.

These are continuous loads (see above).

What about peak amps & for about how many seconds? Just for estimate purposes.

I have made my test rig that goes in 45 increments up to 270amps, when i get rest of the stuff made i field test it with temps and timing. I see little point in theoretical estimate as in true life it could be far different.

[agniusm]

Here is the 6kW tester for end terminals i knocked up today. Possible testing at 45A; 90A; 135A; 180A; 225A; 270A:

[ambroseliao]

Be sure to have your welder's mask on! Or at a minimum, some serious sunglasses!

[Doctorbass]

What purpose are these bulbs made for ?.. 1000W at 24V seem requiring really high current and i can't find wich purpose are for 1000W at 24V.. and 45A !!

Doc

[CamLight]

Here is the 6kW tester for end terminals i knocked up today. Possible testing at 45A; 90A; 135A; 180A; 225A; 270A:

Awesome.
I'm worried about the base plate, and whatever surface the rig is placed on, overheating but testing will show if that's a problem pretty quickly. Have you tested what the initial current surge is for these bulbs? It's typically 5 to 10 times the rated current but I was curious since I've never seen these bulbs before.

[deVries]

I was looking to calculate exactly but it is too complicated. I guess if 20x6.3mm (126mm^2) copper bar is good for 320amps, if i would use 6mm round bar, meaning A=pi r^2=28.26mm^2, i would think that it would be good for 40amps brass or 70amps copper. I might be wrong but then again i am looking more at the clamping of the cells in to the pack and Builder should decide which way to terminate the pack. It is just not viable to design something to individual needs. I need to check current draw in my setup, and i use 14AWG on terminals, BMS and controller are rated at 30A.

These are continuous loads (see above).

What about peak amps & for about how many seconds? Just for estimate purposes.

I have made my test rig that goes in 45 increments up to 270amps, when i get rest of the stuff made i field test it with temps and timing. I see little point in theoretical estimate as in true life it could be far different.

Thank you! for taking the time to do this. Looking for the James Bond naming when you fire it up.

[agniusm]

What purpose are these bulbs made for ?.. 1000W at 24V seem requiring really high current and i can't find wich purpose are for 1000W at 24V.. and 45A !!

Doc

As i will be selling my kit, i have to include information on how much current end terminals will hold. This is the main purpose of the rig. It will draw nearly rated constant current of A123 cells.

EDIT: Miss read the first pars. These were old bulbs for stage lights.

Awesome.
I'm worried about the base plate, and whatever surface the rig is placed on, overheating but testing will show if that's a problem pretty quickly. Have you tested what the initial current surge is for these bulbs? It's typically 5 to 10 times the rated current but I was curious since I've never seen these bulbs before.

I made it from 2mm aluminium sheet so hopefully it will dissipate some heat. I will start at 45amps and probably wont go higher than 130% on calculated theoretical end terminal throughput.

[999zip999]

Sorry Docjoj, I couldn't log in for day's. But I didn't know the real cut-off of the headway bms at bmsbattery. But I wouldn't know. I think Dumm said 3.9v or 3.85v for the headway ? Looking for my 48v 10 fet singalab. from Ping ? Still looking ? I think I will go with 2-36v packs if they fit ? As I would like to get something in hand before I make final choice. Still waiting on John

[agniusm]

Hi. There is a delay with kit as no one seems to be capable to manufacture blocks at reasonable price. This is due the fact that there is a lot of perimeter routing and working with brass is difficult. I cannot use aluminium or copper as they are too soft for the threads and you need that bit of extra nip to get the tabs clamped properly. Whats left is plasma cutting but few firms i rang do not deal with small quantities like mine. Will be looking further in solution to get this issue solved but in the mean time i must apologize for delays and high hopes and just to suggest looking for another solution as i cannot meet my deadlines. I will be posting news her if something real comes up.

[docnjoj]

Hey agniusm
Is the only problem area the brass blocks? If so do you already have the brass in hand? Thanks for your effort and please let me know if I can help. Would you consider selling the kits and materials for the blocks without machine work on the blocks?
otherDoc

[agniusm]

Hi. I was just of the phone taking about manufacturing blocks. The man from the firm was kind and was trying to help with solution. They cant rout the perimeter and he contacted third parties for water jet cut them in to the block. He will get a quote on Wednesday. I have asked him to rout the holes and i will do the tapping manually on this one. Will see how this turns out. Will have to think about the whole thing from different prospective as it is not viable financially to produce this way. I have bought the sheets of material and there is no easy way to cut them within 1mm tolerance. I will try my best to get this done ASAP. All parts are sorted into the kits, connectors soldered, shipping boxes and bags bought, only blocks are missing and i don't want to ship incomplete kits as this will put me in "half job done" supplier position.
I was just informing people who considered purchasing the kit from me that there is a problem and i cannot guarantee speedy completion.
Thanks docnjoj for the offer but i cannot except help, this is my problem to solve;)
Anyway, it does not stop here, there are few designs started for lager applications with kits, some excitement as me and my brother are getting VW Scirocco MKII for conversion next week.
Other thing is even thou people are exited about modules from A123, there might be a slight problem, first on getting them from Chinese vendor and after if something goes wrong with cells inside swapping them with new ones and there will be my kit which will make life easier and still be ok to use with cells from module.
Good day to everyone

[docnjoj]

Thanks for hanging in there agniusm. Let us know if we can help.
otherDoc

[The Mighty Volt]

Thanks for your time and efforts Agnsium, we appreciate it.

[Crashedup]

So any news on those kits, were you able to get those blocks done?

[agniusm]

Hi. Some news. I have met with new manufacturer today and it looks like technologically it's hard to work with brass. I am stuck with few sheets. I have sourced new supplier for 7th series aluminium alloy which is OK to tap and the threads are holding pretty good. Next week this will wil be sorted i hope.
Just need to get those blocks done and as soon as i get them i can start shipping out the kits.
Thanks for taking interest

[docnjoj]

Sounds good to me!
otherDoc
edit: I just ordered a tube of NO-OX to help with the contact surfaces. Seems like it may be a good idea under any circumstances to use this stuff!

[totinen]

Sounds good to me!

Same to me.