A123 AMP20M1HD-A Battery pack kit

[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.

[docnjoj]

I guess it is bump time to prevent this thread from rolling off the edge of the first page!
otherDoc

[deVries]

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!

One thing I read in some tech paper is to use a high-temp "no ox" type product that won't drip/leak once heated. They recommended high-temp petroleum jelly.

[docnjoj]

Thanks deVries. The stuff that I got is supposed to be rubbed off just leaving a really thin coating. Supposedly it "works its way into the metal". We will see. I am only going to be running 40 amps max, usually around 20 or so.
otherDoc

[agniusm]

Sorry guys not coming back so often these days, wedding Saturday coming... Anyhow, got replay from manufacturer, at the moment all is good. Will be arranging materials to be delivered to manufacturer on Monday, and then is up to manufacturer regarding completion time. Will try to push them a little.
Cheers for support

[Spacey]

Congrats on the wedding

[totinen]

[docnjoj]

Sorry guys not coming back so often these days, wedding Saturday coming... Anyhow, got replay from manufacturer, at the moment all is good. Will be arranging materials to be delivered to manufacturer on Monday, and then is up to manufacturer regarding completion time. Will try to push them a little.
Cheers for support

Peace and love man! Weddings take precidence over all else!
otherDoc

[docnjoj]

Just another bump to keep this from rolling of the front page!
otherDoc

[agniusm]

Hi. Was missing there for some time. All is done with wedding, married and all, back on track. Ordered material for blocks. Tomorrow will confirm delivery times to manufacturer.
From the wedding

[docnjoj]

You really do make a handsome couple! Welcome back.
otherDoc

[The fingers]

Congratulations!

[davec]

Congrats!!!!
you need a tandem e-bike-- with a just married sign on the back

[totinen]

Lovely couple. You make me smile.

[megacycle]

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

Any names yet, thinking instant tan equipment or make up mirror light for the seriously vision imparied, ecolighting.
For the James Bond theme, only really Moonraker and Goldmember, i can think, had like a death laser thingamy
and with a decent dish yep it would be visible from the moon :.

Congrats and also Congrats on your excellent battery system, well thought out.

Just some thoughts on the aluminium connection set ups, led to believe that NOX is really for ac connections as a dielectric grease, like a petrol jelly, zinc suspension. i've used a similar type at work on HV a.c. terminations called Alminox.
Some of the A123 cells, also believe have an Al tab for one and a nickel plated (copper ?) for the other and some cells have nickel coated copper for both, so galvanic issues could crop up with the dissimilars and dampness.
There is some research on the subject, but most of what i've found relates to a.c.
In saying that though, quite a bit of it is also relevant to dc connections also.

vol3-3.pdf

(315.8 KiB) Downloaded 23 times

Think a dry connection might work better even though the Al is oxidised.
The greases,might be better used as a moisture barrier which could be recommended if the batteries are out in humid/damp situations where you'd get those galvanic corrosion issues, lightly coating the outer of the whole plates.

[docnjoj]

Hey megacycle
This is the stuff I got. It looks like it should help.

NO-OX-ID "A-SPECIAL" is the electrical contact grease of choice in new electrical installations and maintenance because of its excellent performance in keeping metals free from corrosion. This rust preventitive has been used for over 50 years to preventing corrosion in electrical connectors from low micro-power electronics to high voltage switchgear. NO-OX-ID A-Special prevents the formation of oxides, sulfides and other corrosion deposits on copper and aluminum surfaces and conductors can be prevented with its use. ------------>>>

otherDoc