Converting a rack mounted battery to a triangle battery

Batteries, Chargers, and Battery Management Systems.
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Schalicto   1 µW

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Joined: Jan 16 2018 12:20pm
Location: Minneapolis, Minnesota

Converting a rack mounted battery to a triangle battery

Post by Schalicto » Aug 13 2019 8:06am

Hey everyone. In the spring of 2018 I did an ebike conversion, and at the time mouting a big battery on the rack made the most sense to me, and today it stands as the single biggest mistake in my build. I have broken 3 racks, and I have broken wiring inside the battery's mounting system. I just made the decision to try and take the battery pack out of the big rack mount and fit it into a luna triangle bag. I haven't found a lot of information from others doing this type of conversion, but I'm sure that I'm not the first person who spent a lot on a battery and tried to repurpose the battery instead of just replacing it.

This is the battery that I own
http://recycles-ebike.com/batteries-cha ... 72150.html

The battery features a key ignition switch and a rear light and a usb port for charging accessories, and I don't want to maintain any of those features. I ordered some xt90s connectors to connect the battery to the controller.

Considering that I am new to this battery stuff, I just wanted to check with you guys to see if there is anything I need to know to remove the superfluous components, or repurposing the battery in this fashion. Am I just wasting my time? Please let me know if you have any questions.
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IMG_20190812_184739.jpg (143.41 KiB) Viewed 324 times
IMG_20190812_184818.jpg
IMG_20190812_184818.jpg (157.48 KiB) Viewed 324 times

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Drunkskunk   100 GW

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Location: Dallas, Texas. U.S.A.

Re: Converting a rack mounted battery to a triangle battery

Post by Drunkskunk » Aug 13 2019 6:51pm

Should be easy enough. A battery is just a collection of cells, a BMS (hopefully) and a connector. Are you planning to dismantle the cells and weld them back into a triangle format?

Everything in that second pic can be tossed, although that DC/DC converter might be worth setting aside.
The key switch is interesting. most cheap batteries put that inline with the power lead, which it can't actually handle. It looks like that actually controls the BMS on low power leads, which would make it useful for anti spark connections. Putting a switch in it's place might be useful unless you go for XT90 anti-spark connectors.
Buy the ticket, take the ride.
Monster Bike:http://endless-sphere.com/forums/viewto ... =6&t=38667

Schalicto   1 µW

1 µW
Posts: 4
Joined: Jan 16 2018 12:20pm
Location: Minneapolis, Minnesota

Re: Converting a rack mounted battery to a triangle battery

Post by Schalicto » Aug 14 2019 7:33am

I don't plan on dismantling the cells, assuming that it fits in the luna triangle bag as is.

The Key switch is my biggest question mark. I did order the XT90 anti-spart connectors, so I would prefer to remove the key switch, but the wires for the key switch go up into the shrink wrap around the battery, and presumably terminate into the BMS board. If I want to remove they key switch, can I just wire the two wires for the key switch together?

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Drunkskunk   100 GW

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Posts: 7167
Joined: Apr 14 2007 11:37am
Location: Dallas, Texas. U.S.A.

Re: Converting a rack mounted battery to a triangle battery

Post by Drunkskunk » Aug 14 2019 2:59pm

Yes, should be fine, unless your battery has some feature where you have to turn the key off to charge it. If you can charge with the key on, then no worries.
Buy the ticket, take the ride.
Monster Bike:http://endless-sphere.com/forums/viewto ... =6&t=38667

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