Complete Hobby King Lipo Protection Kit

[methods]

This is a new sales thread for the complete LVC/HVC/Parallel kits with the HVC Charge Breaker and Plug and Play LVC Assembly


DOCUMENTATION -> CLICK HERE

In a nut shell - this helps you to build up Hobby King packs by allowing for easy paralleling of the balance taps, protects your cells from dropping below 3.0V by cutting your throttle, and protects your cells from over-charge by cutting charge current.

You can see the V1 and V2 LVC/HVC/Parallel sales thread here: HVC + LVC + Parallel Boards (Cell Level Protection)
(there is some good info there if you dont quite "get it")

Here is the original build thread: LVC / HVC / Parallel board run - open for suggestions
This shows the progression of the design, why it is good, etc. Long story short my boards draw only 3uA of current from your pack so you can build them into your packs (unlike any of the other products commercially available which draw high current). These boards will never discharge or imbalance your packs. You can build these boards into your pack, run it almost dry, then park it for a year and not worry one bit.

First - here is the Deluxe Super Duper kit

IMG_20120131_102835.jpg (110.82 KiB) Viewed 7625 times

Not everything above is included!
Here is the price list:



$50____LVC/HVC/Parallel Board
$50____HVC Breaker Board (no 12awg cable)
$55____HVC Breaker board (w/12awg 6" pigtails)
$60____HVC Breaker Board (Plug and play Anderson)
$10____LVC Throttle Retard (Plug and play Ebikes.ca)
$5_____JST-XH-7 (6S) 12" Balance tap jumper Price increased because I have to hand build these! Wait for the next batch...
$3_____JST-XH-6 (5S) 12" Daisy Chain jumper (or 5S Balance tap jumper)
$3_____JST-XH-6 (5S) 6" Daisy Chain jumper (or 5S Balance tap jumper)
$2_____JST-XH-7 (6S) 8" Balance tap extension (HK)
$2_____JST-XH-6 (5S) 8" balance tap extension (HK)

Typical kit:
3xLVC/HVC/Parallel boards (18S, three banks of 6S)
1xHVC Breaker board
1xLVC Throttle Retard (you can totally make this yourself....)
3xBalance tap jumper (or make your own from cut up extensions)

So here is how it works:

First, determine how many LVC/HVC/Parallel boards you need. You need one for every 6S in series, so 2 boards for 12S pack or 3 boards for 18S pack. IF you are using 5S packs then you need one board for every 5S in series - so three boards for 15S, four boards for 20S, etc.

IMG_20120131_100932.jpg (139.22 KiB) Viewed 7625 times

That will cost you $50 a pop.
Please note - if you buy only these you will have to wire up your own LVC (easy) and your own HVC (difficult).

The next thing you might consider is taking an HVC Breaker board. These are rated for 30V to 120V service at up to 20A charge current.
You can probably get away with 30A charge current - talk with me if you want to run more
Note: These do not come with any pigtails!

IMG_20120131_100553.jpg (93.77 KiB) Viewed 7625 times

Optionally I can solder on some 12AWG noodle cable for you for $5 and Anderson connectors for another $5. This would make you plug and play with ebikes.ca gear - just plug this inline between your charger and your system. NOTE: THIS DOES NOT GO BETWEEN THE PACK AND THE CONTROLLER. Only between your system and the charger. This board is intended to be built into your pack and left there.

IMG_20120131_100607.jpg (100.89 KiB) Viewed 7625 times

Here is how it works:
Normally - just plug in your charger and charge away!
If for some reason one of your cells gets overcharged this breaker will "lock up" and terminate charge. If this happens, please inspect your pack to determine the problem. After you have solved the problem - just press the green RESET button and you will be able to charge again.

The system is in the "ready" state - no need to press the RESET button unless something goes wrong. Thresholds are set at 4.29V so you should NOT need to press this button very often.... If you do, consider lowering your charge voltage or balancing your pack.

This is intended to be used with a BULK CHARGER - I.E. a CC/CV power supply, BMSBattery Charger, or other Full Pack Voltage charger that runs at a constant charge current. It will work fine with "smart" (aka retarded) chargers like Zivan as well. (Chargers that must "see" the battery to start). There is no blocking diode in this system.

Now -
To use the LVC functionality you need to tap into your throttle lines and solder in a 1K resistor between the tap and the throttle. This has been beaten to death in the other threads, so if you are scratching your head right now just buy this nice adapter that Matthew made for you.

IMG_20120131_101009.jpg (113.43 KiB) Viewed 6970 times

Another goodie you should consider is some way to jumper out your balance tap connections. How are you going to attach your balancers??? This means you need a double ended 5S or 6S cable for each board. Those who are DIY inclined can make these by cutting up 6S Extension cables from Hobby King.

IMG_20120131_101244.jpg (89.9 KiB) Viewed 7625 times

I have some other flavors too (not all pictured)

6S/5S 12" jumper (for use with Battery Medic, balancer, or diagnostic)
5S 6"
Then we have extensions - these just extend your balance taps and are available at Hobby King
5S/6S 8" Extension

IMG_20120131_101448.jpg (101.02 KiB) Viewed 7625 times

So yea... this ad has gotten long enough.
I have 10 of the HVC Breaker boards and as soon as those are out the sale price over. We are basically selling these below cost.

Eventually all this crap will end up on my Website but for now I am at a dead sprint just trying to support my existing customers.

I am backed up about 15 PM's already - first come first served.
I will be shipping out orders today and tomorrow and I expect these to sell out almost instantly.
Parts are on order for a second production run.

Payment will be PayPal
Shipping will be $5 domestic, $13 Canada, or $17 international USPS Prices went up on Jan 22

If you have more questions please check out either the original sales thread or the last few pages of the build thread. Any questions you can think of have probably be answered. UTFST right?

Most orders will ship out in a day. IF you want custom stuff like pigtails or Andersons it will add a day or two depending on how busy things get.

thanks,
-methods

[Arlo1]

Awesome Awesome Awesome!!!!!!

[binlagin]

Hi Methods,

I'm looking for a LVC cut off for the following configuration.

10packs x 6s

I'm planning on running this in a 30s 2p configuration. I've looked at your boards in the past.. but I just couldn't quite grasp what I'd need to do to get this configuration to work.

I'm defiantly interested, if your able to help me out!

Thanks

[ohzee]

Wow I like the look of that and the throttle option.. looked up retard on dictionary.com = to make slow all good I take it back...
Still I will be ordering that option when I get to the point of getting these... great work man I am very impressed. Thanks
for all the efffort.

[liveforphysics]

This is really really really cool!

I feel like I could put RC LiPo on a bike for a mom, and feel pretty good that I wasn't just burning her house down, and feel pretty good that she wasn't going to just destroy the pack from over-discharge on the first ride that she forgets to pay attention to the pack SOC.

[ryan]

Well organized, Methods!

CLARIFICATION
All you see pictured with the LVC is included! The extra jumpers are optional add-ons, but for most each LVC comes ready to plug-n-play!


PM sent, but here's my order:

Code: Select all

Price  QTY   Subtotal   Description
-----------------------------------------------------------------
$ 50    3    $150       LVC/HVC/Parallel boards
$ 30!!! 1    $ 30       HVC Breaker (no cable)
$ 10    1    $ 10       LVC Throttle Retard
$  3    8    $ 24       JST-XH-7 (6S) 18" Extension          ***
$  3    6    $ 18       JST-XH-7 (6S) 12" Extension          ***
$  3    2    $  6       JST-XH-7 (6S) 18" Balance tap jumper ***
$  3    4    $ 12       JST-XH-7 (6S) 12" Balance tap jumper
-----------------------------------------------------------------
SUBTOTAL     $250
SHIPPING     $  5
TOTAL        $255


*** You don't have these listed, but could I get a handful made on the assembly line?
!!! If the discounted ones are still available


[gensem]

Looking real nice... congrats Methods.

[crusoe]

So what sort of charger would you recommend for this setup if I were to run 88v 15ah? If my understanding is correct, these boards do the work of all the balancing and HVC that some chargers may have built in already?

[dougnutz]

I have been running these boards for a month now and the piece of mind they provide is awsome. I only wish I had let Methods build up the throttle retatrd jumper, rather than go through the trials myself. It's totally worth the money.

I have been anxiously waiting for the HVC cut boards (PM sent)

@Methods- my home owners insurance should be giving you a kickback for helping me prevent a fire

[methods]

Well organized, Methods!

The one thing you may want to clarify is what's included with the LVC. The image could lead some to think that the jumpers are included (particularly the extra jumper to HVC that says "included" in the picture).

Everything in that picture is included with an LVC/HVC/Parallel board. Enough Daisy chain jumpers to link the boards together + one to go off to your HVC Breaker + 1 extension to cut up. I think the confusion is over daisy chain jumpers vs balance tap jumpers.

I include all of the jumpers needed to link the communications of the boards.
I do not include jumpers to bring out your balance taps

Underneath it says "That will cost you $50 a pop." But it's a little unclear what you get for that $50. I thought it's just the LVC board + heat shrink + throttle tap (not retard, just cables). JSTs extra. At least that's how I read it when I submitted my order.

We can fix your order. You paid for more than you needed to.
Maybe once we get this cleared up you could go back and edit the list so as not to confuse.

-methods

[dougnutz]

So what sort of charger would you recommend for this setup if I were to run 88v 15ah? If my understanding is correct, these boards do the work of all the balancing and HVC that some chargers may have built in already?

They don't balance, You can plug in a balancer, such as the battery medic, into one of the parallel boards. You would need one balance per board or you can move it from board to board after balancing one pack.

[methods]

10 x 6S packs
30S2P
30S10Ah
5 x 6S blocks

So you would need 5 of the LVC/HVC/Parallel boards and one LVC Retard assembly if you want plug and play LVC protection.
Add 5 x JST-XH-7 if you want your balance taps coming out

You will then be able to expand out to:
30S15Ah
30S20Ah
...
30S40Ah

-methods

Hi Methods,

I'm looking for a LVC cut off for the following configuration.

10packs x 6s

I'm planning on running this in a 30s 2p configuration. I've looked at your boards in the past.. but I just couldn't quite grasp what I'd need to do to get this configuration to work.

I'm defiantly interested, if your able to help me out!

Thanks

[methods]

Correct.
These do not balance. They are for paralleling your packs at the cell level, protecting against cell level LVC, and protecting against cell level HVC.

You would use a 100.8V 10A CC/CV power supply or charger
Each board (4 of them) would need a "balance tap" coming out
To balance you would use 4 x Battery Medic ($15 each) or whatever you prefer.

As we have suggested in another thread:

* Try a BMSBattery Charger - we are ordering 4 or 5 of those. This subject (Bulk charging) has been covered in the Battery Section
* Try a Battery Medic set to 4.0V for balancing. One per 6S board. Just charge up your pack and hang a medic on there overnight. We have 30 of those on the way from China.

So what sort of charger would you recommend for this setup if I were to run 88v 15ah? If my understanding is correct, these boards do the work of all the balancing and HVC that some chargers may have built in already?

They don't balance, You can plug in a balancer, such as the battery medic, into one of the parallel boards. You would need one balance per board or you can move it from board to board after balancing one pack.

[methods]

Yes... although sometimes folks use the term "retard proof" to describe a very simple system, the term "throttle retard" in this case is a technical term for an assembly that will cut your throttle in the case of a cell hitting 3.0V.

-methods

Wow I like the look of that and the throttle option.. looked up retard on dictionary.com = to make slow all good I take it back...
Still I will be ordering that option when I get to the point of getting these... great work man I am very impressed. Thanks
for all the efffort.

[Alan B]

Very nice!

[crusoe]

Hm, I don't understand how I'd only need 4 Battery Medics if I have 8 batteries.

[amberwolf]

cuz if they are parallleed in pairs htru the boards, you only need one per pair.

[crusoe]

Doh, of course.

Let's make sure I understand. http://www.bmsbattery.com/alloy-shell/28-alloy-shell-900w-lifepo4li-ionlead-acid-battery-ev-charger.html

Would be fine?

Also, one last clarification. Is it 3x LVC/HVC/Parallel boards, for $50. Or are they $50 EACH? The pictures are confusing

[fractal]

Doh, of course.

Let's make sure I understand. http://www.bmsbattery.com/alloy-shell/28-alloy-shell-900w-lifepo4li-ionlead-acid-battery-ev-charger.html

Would be fine?

this would work. But what I would like to know is how do you determine the values in the "product customization" fields for a 24s3p pack?
Battery type :
Charge voltage :
Charge current :
AC voltage :
AC plug :
DC plug :

[gensem]

Doh, of course.

Let's make sure I understand. http://www.bmsbattery.com/alloy-shell/28-alloy-shell-900w-lifepo4li-ionlead-acid-battery-ev-charger.html

Would be fine?

this would work. But what I would like to know is how do you determine the values in the "product customization" fields for a 24s3p pack?
Battery type : li ion
Charge voltage : 100.8v
Charge current : 8a
AC voltage : your call 110v or 220v
AC plug : your call too, just ask the wall plug format you use.
DC plug : your call too, that depends on the connector you have in the battery pack.

[ryan]

I thought you're supposed to set it to 4.1v or 4.15v per cell (not 4.2v as you did)? No? Either way, they're charging more for shipping or something because I can't get even close to what Methods was able to get it for. He said it shipped for $125. I can't get it below $150.

[amberwolf]

Also, one last clarification. Is it 3x LVC/HVC/Parallel boards, for $50. Or are they $50 EACH? The pictures are confusing

Each.

[dougnutz]

I thought you're supposed to set it to 4.1v or 4.15v per cell (not 4.2v as you did)? No? Either way, they're charging more for shipping or something because I can't get even close to what Methods was able to get it for. He said it shipped for $125. I can't get it below $150.

I ordered mine with 4.13v per cell. I think even that may have been a little bit high, but I plan to monitor the balance closely. If I had it to do over again I would choose 4.1v per cell.

As for the cost, their shipping is expidited. I ordered mine and it was on my door within a week, including the customization. Infact it was less than 48hrs from China to my door. In Methods case I think he probably recieved a bulk discount and choose a slower/cheaper shipping option.

FWIW you don't have to get a 900w charger either, they offer lower wattage chargers such as EMC-400 (http://www.bmsbattery.com/alloy-shell/26-alloy-shell-400w-lifepo4li-ionlead-acid-battery-ebike-charger.html) that provide the same customization. Obviously they are not as fast but if you can wait twice as long it will cut the price in half.

[methods]

You can turn the voltage down a long way but you can only turn it up a little.
Order your charger for 4.2V/cell

Then if you want to charge to 4.15V/cell just do the math, open it up, reference Doc's thread, and adjust.

-methods

[rojitor]

Lipo made easy... Bravo methods!