36V (3x12V) Pb battery replacement

Batteries, Chargers, and Battery Management Systems.
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nuxland   100 W

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36V (3x12V) Pb battery replacement

Post by nuxland » Sep 12 2020 5:17am

Got one old scooter to my son who is going to university. But it had 3x12V 12Ah Pb battery inside that only allowed around 12km of range. And the charger was 1,5A, so 8h to fully recharge again.
Goal was to put the replacement battery to the same place so I had size restriction. After calculation I sourced 120pcs of "Samsung INR18650-35E 3450mAh - 8A - refurbished" and configured it in 12p10s. nkon holders if combined to 8x15 arrangement were a little to big so bough from aliexpress ready made one pice 8x15 holder and also bough from the same place 6p wide nikkel. As 12p 8A cells can give over 100A but I only needed 30A (that is what brushed motor and 1kw dc controller was rated for) I bought 60A BMS from aliexpress because these were still in the right size. If you go over 80A or 100A they are to large.
This was my first time to use welder that was sitting in shelf from year 2017 :)
Used 100Ah car battery because my lipos were 7s and that is to high for welder mosfets.
36V_40Ah_Weld_Begin.jpg
36V_40Ah_Weld_Begin.jpg (195.98 KiB) Viewed 655 times
Added second layer nikkel where there was only 3 ribbon in series
36V_40Ah_Weld.jpg
36V_40Ah_Weld.jpg (134.18 KiB) Viewed 655 times
BMS installed and output wires done
36V_40Ah_BMS.jpg
36V_40Ah_BMS.jpg (143.18 KiB) Viewed 655 times
New Battery weight without bag and padding (add few hundred grams)
36V_40Ah_Weight.jpg
36V_40Ah_Weight.jpg (120.73 KiB) Viewed 655 times
Old Pb Battery weight
36V_12Ah_Weight.jpg
36V_12Ah_Weight.jpg (104.07 KiB) Viewed 655 times
Testing is it working before shrinkwrapping
36V_40Ah_Testing.jpg
36V_40Ah_Testing.jpg (125.08 KiB) Viewed 655 times
Shrink wrapping (also added extra balance wire just in case when I want to charge it with my 4010 duo)
36V_40Ah_ShrinkWrap.jpg
36V_40Ah_ShrinkWrap.jpg (129.38 KiB) Viewed 655 times
Ready and installed in bag. Only difference from outside is XT90 connector
36V_40Ah_Ready.jpg
36V_40Ah_Ready.jpg (62.77 KiB) Viewed 655 times
In Calculations scooter should have now 4 times the range and battery is 5kg lighter.
Bought also 42V and 5A aliexpress charger to be able to charge it in 8h when empty.
Electric kart 60kw: viewtopic.php?f=34&t=68543
100v 35Ah LiPo battery: viewtopic.php?f=14&t=97763
100v 25Ah LiFePo4 battery: viewtopic.php?f=14&t=85912
Scooter battery: viewtopic.php?f=14&t=108227#p1582703

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nuxland   100 W

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Posts: 258
Joined: Apr 04 2015 2:18pm
Location: Tallinn
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Re: 36V (3x12V) Pb battery replacement

Post by nuxland » Jan 01 2021 6:58am

Made another one and now have two of these.
Attachments
36V_40Ah_SecondOne.jpg
36V_40Ah_SecondOne.jpg (158.24 KiB) Viewed 408 times
Electric kart 60kw: viewtopic.php?f=34&t=68543
100v 35Ah LiPo battery: viewtopic.php?f=14&t=97763
100v 25Ah LiFePo4 battery: viewtopic.php?f=14&t=85912
Scooter battery: viewtopic.php?f=14&t=108227#p1582703

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Ianhill   100 MW

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Re: 36V (3x12V) Pb battery replacement

Post by Ianhill » Apr 26 2021 3:09pm

Whats the range increase, 50 km total there about ?

I had one these years ago for cheap and enjoyed it stock it was terrible but new controller and batterys at 16s 60amp and the ride became alot more enjoyable nippy enough to keep up on 30mph roads no issues.

I stopped riding the roads in the end though felt vunrable in uk everyine wanted to race it and thsts an issue when im going 45mph flat out with a white van up my arse pushing rather than going round some people are just dangerous no matter what they drive.
Infinite hrspwrs.

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nuxland   100 W

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Posts: 258
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Location: Tallinn
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Re: 36V (3x12V) Pb battery replacement

Post by nuxland » Apr 26 2021 4:03pm

Ianhill wrote:
Apr 26 2021 3:09pm
Whats the range increase, 50 km total there about ?
About 35km with one battery. Old brushed motor and controller are ineffective. And its heavy also.
30km/h is max with 36v battery.
Last edited by nuxland on Apr 27 2021 12:52am, edited 1 time in total.
Electric kart 60kw: viewtopic.php?f=34&t=68543
100v 35Ah LiPo battery: viewtopic.php?f=14&t=97763
100v 25Ah LiFePo4 battery: viewtopic.php?f=14&t=85912
Scooter battery: viewtopic.php?f=14&t=108227#p1582703

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Ianhill   100 MW

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Posts: 2596
Joined: Sep 25 2015 5:55pm

Re: 36V (3x12V) Pb battery replacement

Post by Ianhill » Apr 26 2021 4:54pm

nuxland wrote:
Apr 26 2021 4:03pm
Ianhill wrote:
Apr 26 2021 3:09pm
Whats the range increase, 50 km total there about ?
35km with on battery. Old brushed motor and controller are ineffective. And its heavy also.
30km/h is max with 36v battery.
Didnt see it was the brushed motor i got a razor build now with one but like you say range is not the best with these even if they double as a hand warmer when its cold.

Check out the 48-60v 45amp controller in my thread im running its a steal and well suited to these motors specially the 48v and hall throttle works with 12 to 16s
Infinite hrspwrs.

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