Tppacks.com, Zippy Lipo 48v 15ah, LVC and Hyperion 1420i

[Ypedal]

Went digging and found gary's original thread on the 1420i charger:
viewtopic.php?f=14&t=23362

(* still missing pictures.. grrrr.. )

[GGoodrum]

If you start out with balanced cells/packs, I think it is fine to parallel just the main 12s +/- connections, and not parallel the intermediate connections. This is how I've been building LiPo packs since the beginning. All the cells are still paralleled at the cell level.

--Gary

[Planky]

nieles, It sounds simple what your explaining but can you please make a drawing.
Thanks

I vote for a drawing too.

[Ypedal]

Ok, so we are charging !!

I set the capacity to 15,000 mah ( 15ah ) .. the user settings i gave it " 1C " .. hooked it up to an SP-480-24 cranked to 27.0v .. and set Mem-1 to 15 amps... i only get 7.33 amps from the charger ???

[johnrobholmes]

What is the charger input voltage? Sounds like you are using 12v. The charger needs 24v to get the full power, and I do believe there may be a setting hidden in the setup menu to change the max wattage to the full capability. I know other Hyperion chargers are like that, but I haven't gotten into those details of mine yet.


I haven't been paralleling my cell chunks under 12s, so I don't have bridges on the 6s level either. I also don't take out the last amp hour or two of the pack. Never had a problem with it, the only problems I have are runt cells.

[Ypedal]

Post above.. I"m now using a proper power supply set to 27v ..

[nieles]

okay here is the drawing for the people asking for it:

parallel series.JPG

(129.39 KiB) Downloaded 4 times

On the left: the cells are first connected in series to get 12s strings, then the 12s groups are connected in parallel at the pos and neg terminals.

On the right: all cells are first connected in parallel, then the series connecion is made.

[Ypedal]

Ok.. understood... however with the TP pack boards it becomes something like this :

parallel%20series[1].TIF

(12.32 KiB) Downloaded 4 times

The only segment not paralleled is the one between cell group 6 and 7 .. the rest are all in P..

I imagine better current handling having the packs connected by 3 wires would be better imo..

[johnrobholmes]

Did you also change the wattage setting of the input? I think that may be an option too.


Sorry for the lack of reading comprehension, I was a bit drunk last night I read the entire thread looking for the info and it was right above my head

[Ypedal]

Cut and bent some 1/4" ABS plastic, drilled holes for the wires, hot glued the pack to the ABS and wrapped a few layers of tape behind the wires with glue so that when the wires get tugged they dont come un-done from the parallel harnesses.....

[Ypedal]

On the charger for a top-off...

[Ypedal]

I put a CA between the charger and power supply...

[Ypedal]

13.2 Lbs !!!

[Ypedal]

120 x 175 x 195 mm

Done !

Battery, Meet bike ( i need a picture of the bike hehe )

[visuthdy]

Ypedal,
thanks for a great tutorial, I've got the same kit from Gary a while back and know I know how to build one. I'm planning on running (4) 6S 5000mah zippy batteries in 12s2p setup.

[Ypedal]

Well now.. imagine this... i just got off the phone with Mr.B and aparently.. somehow... upon connection of the new pack to the controller the andersons vaporized into plasma and caught fire !!!!!!

WTF ?????

I even installed a 70 amp fuse prior to it leaving here and the fuse did not pop, he swears the polarity was right...

Having him bring the bike and pack back here tomorrow for further investigation but i'm at a totall loss to explain what the hell happened... i have connected 1000's of times various anderson assemblies from 12 to 100v and have NEVER had this happen... i've had them stick and spot weld themselves a few times but a few wiggles and they snap in place but never any fireworks... ever...

[Ypedal]

Say hello to Mr. Crispy !

[Ypedal]

After investigating the remains i determine that it was an accident on the new guy's part !

Impossible to tell via the tips of the andersons, they are gonners, but the box ends of the powerpoles are still there and i can tell that with male sides facing up on both ends, it would be impossible to make a proper connection, so they were plugged in reverse polarity !!!

PPburn2.JPG (32.94 KiB) Viewed 1395 times

I cut the cables back and re-crimped fresh andersons, checked pack voltage at 50.2 volts, good... Then hooked it up to the controller and it powered on as expected, no fireworks this time !!.. and all is still working correctly !

I would have expected the controller to smoke but it did not !!! Phew !

[liveforphysics]

Newbs can wreck anything in a split second. lol My intern smoked a giant SB120 Anderson connector like that on a perfectly made pack I gave him to test. Connected it backwards. lol

You did an outstandingly nice job on the pack my friend.

[nicobie]

I thought it was impossible to plug in Andersons wrong? Did he change the way they were hooked together? I'm sticking to HX60s and quality bullets.

[Ypedal]

I tested the pack on my bikes before handing it over, he was using a few of my spare packs i lent him while working on his so he was already familiar with Andersons.... Howerver.. his bike had the poles reversed from my bikes and he did not pay attention to polarity when hooking it up at 11pm at night in his kitchen.....

[AussieJester]

Haha, I bet it it woke him up quick smart though YPedal Man! All Drousy, about ready for bed likely one or two wines later lol..then ZAP! Scares the beejesus out of you when your half expecting it, could only imagine the shock when your not....

Good to see no Penang damage to anything else

KiM

[knoxie]

Super job on the pack buddy (for a blind man ) but am amazed the controller survived that! flipping amazing! the andersons acted as a fuse there and I know what it is to make a connection mistake too, did that when I first built my pack, got distracted by a phone call, came back and vaporized all my balance wires splitting my brand new batteries and soldering new balance leads kinda has made me pay 100% attention when changing or modifying the pack.

[Ryank]

....maybe we should cover just exactly what it is that is wrong in that picture Mr Ypedal(?) Just for the newbies here and in the future......NOT for me...
Becasue I'm sure some of the less-experienced people might look at that photo (red wires/red connectors & black wrires/black connectors-facing eachother) and think that is oaky..!!
Funny, I bet some body (right now) has a garage full of great batteries/contorllers that are all blown up and...... I still can't figure out why???

Thank you,

Ryan

[Ypedal]

Good point.

If you look at the picture below, see how the Male/Female dove-tails on the blocks can only fit a certain way and plug Red-Red and Black-Black if those dove-tails are oriented properly.

From the residue in the picture above, I can confirm that they were plugged reverse polarity by looking not at the tips, but at the ends of the blocks.