Show off your lipo setup!

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

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Show off your lipo setup!

Post by moostrodamus » Apr 25 2010 7:16am

I want to build a lipo setup with some RC packs. In researching I realize there are a lot of options with regards to rc packs, chargers and balancers...

Show off your pack! What charging method do you use, what cells, what chargers etc. Include some pics if you can...I don't read so good!!!

Moos
Commuter: Crystalyte HS3540
Infineon 40 amp controller
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Metallover   10 kW

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Re: Show off your lipo setup!

Post by Metallover » Apr 25 2010 10:35am

I run six 5ah turnigy packs at either 66.6v (or 44.4v if I desire). I charge them with a hyperion eos0610i charger. I need to charge them as a 30ah 6 cell pack, and I charge and balance them induvidually every few cycles. The charger is rated for 250w output and has a built in balancer. There is a charger link feature; if you have two identical chargers you can charge 12s packs at 500w. The biggest downside of one charger is the 6s max lipo capability.

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Bazaki   10 kW

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Re: Show off your lipo setup!

Post by Bazaki » Apr 25 2010 3:10pm

Metallover wrote: The charger is rated for 250w output and has a built in balancer. There is a charger link feature; if you have two identical chargers you can charge 12s packs at 500w. The biggest downside of one charger is the 6s max lipo capability.

Do you mean you put 2 chargers in Serie to the 12S pack ? Would that work 100% ?

Would it also be possible to put 2 indentical chargers in parallel ?

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Metallover   10 kW

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Re: Show off your lipo setup!

Post by Metallover » Apr 25 2010 3:31pm

This feature is specific to hyperion chargers. You might be able to hook other chargers together, but I don't know anything about that.

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This is what I am talking about. The chargers hook together with a little cable that just sends data.
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My Build - Vector Frame, 20s 25Ah LiPo, Max-E, Cromotor - 10.89HP on the Dyno

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Don Harmon   10 kW

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Re: Show off your lipo setup!

Post by Don Harmon » Apr 25 2010 5:03pm

Do you ride your bike with these Lipo Packs exposed like you show in the picture?

DH

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Metallover   10 kW

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Re: Show off your lipo setup!

Post by Metallover » Apr 25 2010 5:25pm

ATM I have a towel I wrap around them and I duct tape that to secure it.

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The way I mounted the batteries,, It takes some work to make a nice enclosure. If I plan to leave the bike locked up in public, I'll really need something pedestrian-proof. I am working on a better enclosure, ideas welcome. The one I have right now, I don't think it'll work out because I dont have access to a welder. :|
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wasp   10 kW

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Re: Show off your lipo setup!

Post by wasp » Apr 25 2010 6:37pm

Metallover wrote:ATM I have a towel I wrap around them and I duct tape that to secure it.

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The way I mounted the batteries,, It takes some work to make a nice enclosure. If I plan to leave the bike locked up in public, I'll really need something pedestrian-proof. I am working on a better enclosure, ideas welcome. The one I have right now, I don't think it'll work out because I dont have access to a welder. :|
lmao...
look at some of the vinyl rain pipe for houses they make cheap bat housings and no welding required
nice bike to

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AussieJester   100 GW

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Re: Show off your lipo setup!

Post by AussieJester » Apr 25 2010 7:33pm

I (currently will be increasing) use 6x22v 5000mah 20c Turnigy packs 44v 15ah
weight is 11 pound or 5kilo. I use GGoodrum parallel adapter boards (see sig for link)

Here's a pic of my pack

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And the cable I made to parallel the packs in series.

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I use a meanwell 320-48v PSU to charge the pack (in series/parallel config) and a Battery medic to balance (will soon
have GGoodrum charge controller and battery medic mod .see link for these also)

Lipos are housed in a custom fiberglass enclosure i made.
e-crusier.JPG
e-crusier.JPG (184.15 KiB) Viewed 544 times
Turnigy meter is used to monitor battery during riding

KiM

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moostrodamus   100 W

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Re: Show off your lipo setup!

Post by moostrodamus » Apr 26 2010 3:17am

Thanks Metallover & AussieJester ,

Pics of connections and chargers help alot, I can SEE how stuff gets hooked up...just the way my brain works.

Moos
Commuter: Crystalyte HS3540
Infineon 40 amp controller
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ryan   10 kW

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Re: Show off your lipo setup!

Post by ryan » May 07 2011 6:40pm

I think this thread ended too soon. I'd love to see more.
Marin DH Electric Mountain Climber. Crystalyte 5304. 72v20Ah (Dual 36v20Ah 12S2P LiFePO4 Headways). 18 FET Low RDS MOSFET Overclocker Ready LYEN Controller. (See Build Thread)

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AussieJester   100 GW

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Re: Show off your lipo setup!

Post by AussieJester » May 07 2011 8:10pm

Since you asked...Here's my new bikes 12s 2p (44v 20ah) LiPO setup...Using 3mmx~8mm thick copper bus bars too parallel/series the main pack
leads. The balancing leads are parallel ed using modified GGoodrum parallel adapter boards available from http://TPPacks.com

Here's some pics of the construction-->

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The parallel leads and main charging leads are then connected to a DB25 connector for easy connection to the Hyperion 1420i
charger. I can then bulk charge at ~50V with simultaneous balancing... Main pack leads run via a 12v 400amp capable
battery isolation switch before bolting to another small set of buss bars where additional wires are added for powering
dc/dc converters etc etc...Apologies no pics of this part of the setup at the time i had no access to camera mine failed
not long after taking the bus bar pics.

Hope this helps :-)

KiM

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dogman dan   100 GW

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Re: Show off your lipo setup!

Post by dogman dan » May 08 2011 5:38am

A mo bettah way to carry some lipo on a mongoose blackcomb.
CIMG0179.JPG
At this time, I actually have a smaller box on the mongoose, which carries 72v 10 ah. But the key element is something a bit more protective than some tape and a towel.

Every time I see lipo just taped to the frame I cringe. I'll assume AJ just left out the pic showing his side covers that protect the batts and beautify the bike.


Here's my charging rig.
CIMG0007.JPG
A 350 watt power supply runs the two 8s 150 watt chargers. With paralell adapters, I can charge the whole pile shown at once. Usually though, I charge them in paralelled pairs, so two pairs at a time.

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rscamp   1 kW

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Re: Show off your lipo setup!

Post by rscamp » May 08 2011 8:25am

Some pics...
Attachments
Battery Charging Table.jpg
Table devoted to battery charging/maintenance
Battery Charging Table.jpg (35.21 KiB) Viewed 6504 times
Orbit Microlader Pro and TP1010C Chargers.jpg
Some older hobby chargers
Orbit Microlader Pro and TP1010C Chargers.jpg (51.22 KiB) Viewed 6495 times
Hyperion 1420i With Balance Cable Extensions.jpg
Hyperion 1420i with extended balance cables
Hyperion 1420i With Balance Cable Extensions.jpg (45.97 KiB) Viewed 6495 times
Meanwell 27V 1000W Power Supply.jpg
27V 1000W Power supply for Hyperion
Meanwell 27V 1000W Power Supply.jpg (40.82 KiB) Viewed 6495 times
Power Resistors.jpg
Power resistors for battery testing
Power Resistors.jpg (49.75 KiB) Viewed 6495 times
Battery Pack.jpg
Battery pack for ebike - made with heat shrink and aluminum reinforcements for corners
Battery Pack.jpg (28.03 KiB) Viewed 6504 times
_DSC8174.jpg
Battery installed in ICE trike
_DSC8174.jpg (54.38 KiB) Viewed 6504 times
Rob
Trice QNT with Astro 3215 8T & V4 Drive
Trice Q with Bafang BBS02 at 48V with "500W" limit
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rui_fujino   1 kW

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Re: Show off your lipo setup!

Post by rui_fujino » Feb 02 2012 12:07pm

I've noticed this thread hasn't been used for a while but since I got new lipo setup completed I thought I'll post them here!

I think it helps new lipo users to see what we do is working here on pictures rather than them asking what to do and telling them what to do...

Here is my 20s2p setup. I'm using 8X5s turnigy packs and I have paralleled balance charging tabs for balance charging with battery medics
IMG-20120131-00502.jpg
This is battery medics when its bulk charging to keep all the cells balanced
IMG-20120131-00501.jpg
BMSBattery charger on the back for bulk charging
IMG-20120131-00500.jpg
Project 1: Apollo slant hard tail MTB 52v lifepo4, conhismotor, 52T-11T gearing 39.6mph top speed (with pedal)
Project 2: Diamondback s:10 Full suspension 20s2p (83.5v 10ah Lipo), 35kg, HS3540 sensored (MethTek), 12FET lyen controller, Bulk 600w balance charger.
Top speed 45mph(72.4km/h)
Project 3: DOPPELGANGER d2 Visceral
Project 5 Specialized Epic20s2p (83.5v 10ah Lipo), 30kg,HS3540 sensored (MethTek), 12FET lyen @ 50A
Top speed 45mph(72.4km/h)
EV miles: 3000miles (2015/06/26)

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Re: Show off your lipo setup!

Post by kfong » Feb 02 2012 1:45pm

Go with the 1420i and you can go as high as 28S when 2 are networked together. Best charger for ebike use that I have found.
Metallover wrote:This feature is specific to hyperion chargers. You might be able to hook other chargers together, but I don't know anything about that.

Image

This is what I am talking about. The chargers hook together with a little cable that just sends data.

emergence   100 mW

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Re: Show off your lipo setup!

Post by emergence » Feb 08 2012 3:07am

This is a great thread for us Lipo newbies. Please keep posting!

Also re charging I'm still pretty confused about the whole process. I take it if you want to have a single plug solution for charging then you need to make up a series to parallel adapter like AussieJester, disconnect (or use a switch) the pack from your speed controller including the series connections, then plug the parallel connector into the charging rig.

Thanks everyone!

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Re: Show off your lipo setup!

Post by emergence » Feb 08 2012 3:38am

And I just spotted this which should answer a lot of questions:

http://endless-sphere.com/forums/viewto ... 14&t=23551

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amberwolf   100 GW

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Re: Show off your lipo setup!

Post by amberwolf » Feb 08 2012 3:45am

emergence wrote:I take it if you want to have a single plug solution for charging then you need to make up a series to parallel adapter like AussieJester, disconnect (or use a switch) the pack from your speed controller including the series connections, then plug the parallel connector into the charging rig.

Nope. You can use a setup like Method's HVC/LVC built into your pack, and just bulk charge at the same voltage and configuration you ride at. Every so often if you like you can check balance at each of the paralleled balance plugs on the little boards, using your choice of devices from multimeter to Battery Medic or whatever. If they're out of balance enough to warrant it, then use the BM or something like it to manually balance the cells.

If you're not running them down very far most of the time, they're likely to stay in balance pretty well if they were already cycled and tested good and equal to each other to start with.

But if you like, you can also do parallel-series conversions for each charge...it just adds a slight-to-great potential for disasters like SoSauty's (where the entire pack was destroyed because of an accidental cross-connection), depending on how you setup your changeover from charge to ride and back. It's possible to essentially idiot-proof this kind of setup, and not all that hard to do so. But if you don't do that, then it's possible to misconnect things and cause bad stuff to happen. ;)


I'm sure it's possible to cause bad stuff the other way, too, but I suspect it would happen less often and be less disastrous.


So far all I have had to do is bulk charge, but I don't take the pack down very far, and the one I'm using at the moment isn't RC LiPo, but soon I will be using that, too.

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Re: Show off your lipo setup!

Post by neptronix » Feb 08 2012 4:43am

emergence wrote:This is a great thread for us Lipo newbies. Please keep posting!

Also re charging I'm still pretty confused about the whole process. I take it if you want to have a single plug solution for charging then you need to make up a series to parallel adapter like AussieJester, disconnect (or use a switch) the pack from your speed controller including the series connections, then plug the parallel connector into the charging rig.

Thanks everyone!
Depends on your setup entirely. If you're running up to 14S ( ~52v nominal ), a hyperion 1420 will allow you to charge everything in series.. or even better, balance charge it all..
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emergence   100 mW

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Re: Show off your lipo setup!

Post by emergence » Feb 08 2012 5:55am

neptronix wrote:
Depends on your setup entirely. If you're running up to 14S ( ~52v nominal ), a hyperion 1420 will allow you to charge everything in series.. or even better, balance charge it all..
Yes, sorry I was thinking of 50v plus charging where you get more cells in series than hobby chargers can handle.
amberwolf wrote: You can use a setup like Method's HVC/LVC built into your pack
Thanks that sounds good, will search it out.

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Re: Show off your lipo setup!

Post by Farfle » Feb 08 2012 12:33pm

Heres my battery setup, 24s3p of turnigy nano-tech 50c packs. First wrapped in fiberglass tape to prevent expansion, then a layer of aluminum is added to the top and bottom, then the whole thing is wrapped in gorilla tape. it measures exactly 4"x12"x6" .Everything battery side is wired with triple paralleled 10 awg, and everything motor side is single 6awg. Its all charged with a ggoodrum/fechter "lite" BMS mated to a pair of 48v meanwells.

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Test Review Revise Repeat

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Re: Show off your lipo setup!

Post by corkscrew » Feb 08 2012 3:55pm

I have 8 6S 5amp/hr batteries in a 44.4 20amp/hr setup.

8 mount on either side of my trike in stainless steel battery boxes. 4 batteries on each side make for two 6S 20amp/hr packs. They are paralleled together with a anderson connector harness I made, and some 6S balancing harnesses from progressiveRC. A serial adapter cable connects the two packs, turning the pack into a 12S 20amp hour pack. Charging and balancing are done with a Hyperion 1420 charger, and GGoodrum's 12S one plug charger kit. So every time I charge, I make one connection, and it charges and balances for me.

I have room to add another two bricks per side, which would give me 44.4V (49ish off the charger) and 30 amp hours.

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I just recently broke the pack down after about a year and over 1000 miles. When I checked each battery individually they all were still within .03 of each other. Only broke it down because the chain chewed through some of my balance wires, and was causing wonky readings @ the charger. Just need to decide if I'm going to order another 4 batteries, or seal it all back up again with new heat shrink.

This photo, despite it's crappy quality shows the new longer parralleled balance harnesses I built. Basically just extended the Progressive RC harnesses to eliminate a JST-XH connection, and give a little more distance. You can sort of see the one plug going from the batteries to the charger.

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Here is her all put together. You can see the one plug charge kit hanging off the battery box.

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Actionbent T1 Tadpole Trike - 2806 9C Motor in a 700C wheel. 12S 15AH Lipo pack.

--Build thread: http://endless-sphere.com/forums/viewto ... =3&t=26520

emergence   100 mW

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Re: Show off your lipo setup!

Post by emergence » Feb 08 2012 4:19pm

Farfle wrote:Heres my battery setup, 24s3p of turnigy nano-tech 50c packs. First wrapped in fiberglass tape to prevent expansion, then a layer of aluminum is added to the top and bottom, then the whole thing is wrapped in gorilla tape. it measures exactly 4"x12"x6" .Everything battery side is wired with triple paralleled 10 awg, and everything motor side is single 6awg. Its all charged with a ggoodrum/fechter "lite" BMS mated to a pair of 48v meanwells.
Thanks Farfle, that's a lot of grunt! what is the advantage of using the high C nanotech packs when, as far as I can work out 20c packs in 24s will still put out enough watts and amps to destroy any ebike hub and the wiring too? Voltage Sag?

And thanks for the pics, they really help. Nice build!

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Farfle   1 MW

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Re: Show off your lipo setup!

Post by Farfle » Feb 08 2012 5:24pm

North of 25 kw a 20c turnigy pack will sag like crazy at only 15ah. The high c rate packs just help reduce the voltage sag. and yes, this will destroy any ebike motor, but im not exactly running a normal ebike motor :twisted: :twisted:
Test Review Revise Repeat

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boppinbob   1 kW

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Re: Show off your lipo setup!

Post by boppinbob » Feb 08 2012 6:01pm

20s1p zippy's in a removable battery box so I can easily charge on or off the bike.
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Project bike-Genesis v2100, Crystalyte HS 3540 with 72v40A controller and four 5s8Ah zippy lipos in series.

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