Homemade Battery Packs

Batteries, Chargers, and Battery Management Systems.
User avatar
kje
100 W
100 W
Posts: 177
Joined: Apr 07, 2012 11:55 pm
Location: Oslo, Norway

Re: Homemade Battery Packs

Post by kje » Jan 15, 2016 6:45 pm

I used 16awg wires.

How can I limit/adjust the amps?

User avatar
DrkAngel
10 GW
10 GW
Posts: 4583
Joined: Dec 15, 2010 11:14 am
Location: Upstate-Western-Southern Tier NY. USA

Re: Homemade Battery Packs

Post by DrkAngel » Jan 24, 2016 9:55 am

Been running my 33.3V 43.2Ah pack on my Snow Beast.

Image
22.2V 43.2Ah with add on 11.1V 43.2Ah module
Image
After setting for about 1 year @ ~ 3.90V all cells were equal within 1/100th V.
Charged and balanced ...

Been making all the cars jealous!
I stop quick (studded tires) and watch cars go sliding into, or through, intersections!

Snow Beast has a 36V 25A controller.
I am noticing a marked decline in umph as pack voltage drops off from full.
33.3V charges to 37.35V but sags toward controller LVC (~31V) at full throttle in the cold.
Am considering swapping out 36V controller with the Yi-Yun 24-36V+ capable controller.
This will allow full volts-amps to full battery capacity.

I will monitor pack voltage, use ... manually.
Large pack! Have never neared low voltage.
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

LeftieBiker
1 kW
1 kW
Posts: 322
Joined: Nov 06, 2012 1:33 am
Location: Upstate NY, United States

Re: Homemade Battery Packs

Post by LeftieBiker » Jan 30, 2016 5:05 am

A little off-topic, but I figure this is a good place to ask about this: I just got my new 2015-leftover Ping 24V 20AH pack, and when I connected the BMS and charged it, 7 of the 8 balance LEDs came on within seconds, while the 8th took several minutes to even flicker, and then almost ten minutes to come on full. Should I be worried, or is this sort of initial imbalance normal? I emailed Ping, but haven't heard back yet. I honestly don't remember if this happened with my 2013 pack or not, when it was new.

markz
100 GW
100 GW
Posts: 5225
Joined: Jan 09, 2014 11:38 pm
Location: Alberta Canada

Re: Homemade Battery Packs

Post by markz » Feb 10, 2016 8:38 pm

As I was building my DIY bike 1300 Lumen light, I bought a bunch of copper pieces.

Bushing - https://www.homedepot.ca/en/home/search ... Arelevance
Coupling - https://www.homedepot.ca/en/home/search ... q=9000-005

Couplings are to connect the same size pipe. Bushings are for changing from 1 size pipe to a different size.

LiFePO4 A123 M1A
Fits perfectly
battery pack.jpg
A bit of room with the coupling, can be made snug with tire tubes, tape etc.
I think the bushing is the exact same size as regular copper pipe.
Its not an ideal battery string, because you want parallel first then series. This is an off the shelf idea I have had for some time.
I always tried PVC piping which might be better, but nothing comes close to this fit. The other fits in 1" PVC were very tight. It could be worked around with some sanding down of the ID, how you would go about that I got no clue. 1.25" PVC was a huge gap, but again you can throw some strips of balsa wood in there firm it up quick.

Cooled batteries?
http://www.petersenproducts.com/Specifi ... opper.aspx
Using 1" nominal (1.125" OD) with 1-1/4"
LMFAO, batteries would never last long if you went that way, the need to cool the batteries by under-sizing the battery pack.

User avatar
DrkAngel
10 GW
10 GW
Posts: 4583
Joined: Dec 15, 2010 11:14 am
Location: Upstate-Western-Southern Tier NY. USA

Re: Homemade Battery Packs

Post by DrkAngel » Feb 16, 2016 2:53 pm

I mentioned previously that glass tube fuses-holders weren't holding up too well. (40A)
Well ...
Glass tube.jpg
Glass tube.jpg (157.23 KiB) Viewed 3055 times
Testing for a proper replacement.
7s (29.4V charged) should work nicely with 32V rated automobile blade fuses.
Mini blade looks reasonable and uses less room!
Socket fuses.jpg
Socket fuses.jpg (176.05 KiB) Viewed 3055 times
8ga blade fuse holder seems unnecessarily large.
10ga mini blade holder is much better and with a little rubber seal removal, looks standard blade capable!
(40A fuses available!)
Last edited by DrkAngel on Feb 17, 2016 3:07 pm, edited 1 time in total.
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

User avatar
DrkAngel
10 GW
10 GW
Posts: 4583
Joined: Dec 15, 2010 11:14 am
Location: Upstate-Western-Southern Tier NY. USA

Re: Homemade Battery Packs

Post by DrkAngel » Feb 17, 2016 7:23 am

DrkAngel wrote:I mentioned previously that glass tube fuses-holders weren't holding up too well. (40A)
Well ...

Image
I would not blame the AGC fuse

Fuse holder contacted ends of fuse poorly, creating hot points and eventually arcing which amplified heat!
(Copper end contacts acquired tarnish and corrosion over the years leading to poor contact >> arcing >> high temperature >> tempering copper contacts and detensioning spring >> inflexible contact-poor contact pressure >> worse arcing >> extreme heat etc!)
In vehicle fuseboxes, fuses are firmly contacted on 2 sides of each metal end cap.
AGC 1.jpg
AGC 1.jpg (16.41 KiB) Viewed 3049 times
Other types of holders firmly contact a large area of the end caps, ensuring good contact-low temperature operation.
AGC 2.jpg
AGC 2.jpg (17.28 KiB) Viewed 3049 times
AGC glass tube fuses are typically very durable and compatible with very high voltages due to a very long fusible element.
DC volt rating is dependent on broken link arc distance. Avoid fuse able link with thin center portion = short higher current arc gap.
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

User avatar
DrkAngel
10 GW
10 GW
Posts: 4583
Joined: Dec 15, 2010 11:14 am
Location: Upstate-Western-Southern Tier NY. USA

DC Fuse Availability 32VDC - 58VDC - 80VDC - 125VDC

Post by DrkAngel » Feb 17, 2016 11:10 am

DC Fuses 32VDC - 58VDC - 80VDC - 125VDC

eBike Toolbox _ $

I will be using Mini Blade fuses for my ≤32V batteries ..
and will try
J Case Low Profile for my ≤58V batteries ...
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

User avatar
DrkAngel
10 GW
10 GW
Posts: 4583
Joined: Dec 15, 2010 11:14 am
Location: Upstate-Western-Southern Tier NY. USA

Re: Homemade Battery Packs

Post by DrkAngel » Apr 17, 2016 7:42 am

2 x 7s 25.9V 25.92Ah batteries, several thousand miles on each, are really perking up with the warm weather!
Runs my comfort cruiser 24V eZip LS at ~20mph and my pedal assist 24V eZip at 21mph+ (motor only)
Also helps that tires don't go soft after sitting in the cold.

2015 "Eco Ride", oem gearing, cruises at 17mph+!
For economy and battery longevity I intend on "retiring" one of my 25.9V 25.92Ah packs, dedicated for its use.

2008 iZip Mountain Trailz will receive other.

Building 2 more 7s 25.9V 25.92Ah packs, from cells I tested for unrealized eMotorcycle build.
Will also build a 3s 11.1V 60.48Ah or 51.84Ah w/inverter pack for a dedicated Turbo.
EZips have a 3 position (on\off\on) 2 pack switch.
With a simple rewire, switch can run 7s 25.9V pack (485w motor output) in position 1. - 20mph
Position 2 runs 7s and 3s pack in series for 10s 37V (~695w motor output) - 27mph (30mph w\moderate pedal assist)

Note - eZip RMB battery packs often suffer from poor contact and rattling in rack.
This tends to be annoying and eventually damages locks from rattling and contacts by overheat from arcing.
After several attempted "cures", bending rack, wedges, tape etc ... best solution was simply adding rubber type bumpers under packs.
Precise thickness and density, sizes pack to require modest pressure to lower pack while engaging lock ... works beautifully!
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

1KW
1 kW
1 kW
Posts: 398
Joined: Jul 24, 2013 10:23 am

Re: Homemade Battery Packs

Post by 1KW » Apr 17, 2016 9:11 am

Image

these things be any good in 14s xxP configuration? Im thinking for a bbshd.

User avatar
DrkAngel
10 GW
10 GW
Posts: 4583
Joined: Dec 15, 2010 11:14 am
Location: Upstate-Western-Southern Tier NY. USA

Re: Homemade Battery Packs

Post by DrkAngel » Apr 17, 2016 9:49 am

DrkAngel wrote:2 x 7s 25.9V 25.92Ah batteries, several thousand miles on each, are really perking up with the warm weather!
Runs my comfort cruiser 24V eZip LS at ~20mph and my pedal assist 24V eZip at 21mph+ (motor only)
Also helps that tires don't go soft after sitting in the cold.

2015 "Eco Ride", oem gearing, cruises at 17mph+!
For economy and battery longevity I intend on "retiring" one of my 25.9V 25.92Ah packs, dedicated for its use.

2008 iZip Mountain Trailz will receive other.

Building 2 more 7s 25.9V 25.92Ah packs, from cells I tested for unrealized eMotorcycle build.
Will also build a 3s 11.1V 60.48Ah or 51.84Ah w/inverter pack for a dedicated Turbo.
EZips have a 3 position (on\off\on) 2 pack switch.
With a simple rewire, switch can run 7s 25.9V pack (485w motor output) in position 1. - 20mph
Position 2 runs 7s and 3s pack in series for 10s 37V (~695w motor output) - 27mph (30mph w\moderate pedal assist)
Turbo Switch Thread
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

Geekineer
10 mW
10 mW
Posts: 33
Joined: Nov 23, 2015 7:42 am

Balancing - BMS or smart Charger

Post by Geekineer » Apr 17, 2016 10:41 am

Noob - here -read lots posts but one lingering question.
Building 10S4P pack with Samsung 3E cells (about 3200mah/cell)
Ordered BMS/PCM from BesTechcPower model HCX-D132, rated 10A cont charge, 30A cont discharge.
??? is:
Do I need a charger with balancing leads connected to each cell with this BMS (which I think has balancing)
or just a constant current, 5A, 42V charger i.e. SuPower???

Can someone chime in and/or recommend a charger for above setup.
Much appreciated

User avatar
teslanv
1 GW
1 GW
Posts: 3040
Joined: Nov 03, 2013 8:42 pm
Location: Bellevue, WA - USA
Contact:

Re: Balancing - BMS or smart Charger

Post by teslanv » Apr 17, 2016 12:29 pm

Geekineer wrote:Noob - here -read lots posts but one lingering question.
Building 10S4P pack with Samsung 3E cells (about 3200mah/cell)
Ordered BMS/PCM from BesTechcPower model HCX-D132, rated 10A cont charge, 30A cont discharge.
??? is:
Do I need a charger with balancing leads connected to each cell with this BMS (which I think has balancing)
or just a constant current, 5A, 42V charger i.e. SuPower???

Can someone chime in and/or recommend a charger for above setup.
Much appreciated
If you are wiring up a BMS, all you need is a CC/CV power supply or charger, with the appropriate voltage and Max current output. Options would include the Grin Satiator, or Mean Well PS, or a Kingpan charger.
10A is a pretty good charge rate, but with only 4 cells in parallel, it will be a bit hard on the cells. You would be better to keep the charge rate under 5A.
DD Hubs, Batteries, Controllers & Custom Ebikes.
Free Shipping to the Continental USA
http://www.westcoastelectrics.com
West Coast Electric Cycles
Bellevue, WA
USA

Geekineer
10 mW
10 mW
Posts: 33
Joined: Nov 23, 2015 7:42 am

Re: Homemade Battery Packs

Post by Geekineer » Apr 17, 2016 2:03 pm

Thanks - I'll check out the chargers you suggested?
Yes - 5A preferred max charge rate. 10A was just the limit of the BMS.

User avatar
DrkAngel
10 GW
10 GW
Posts: 4583
Joined: Dec 15, 2010 11:14 am
Location: Upstate-Western-Southern Tier NY. USA

Re: Homemade Battery Packs

Post by DrkAngel » Apr 18, 2016 5:05 am

See - MeanWell Mods - S-150-48
For budget 42V 3A+ charger.
Includes instructions for voltage and amperage mods-adjustments.
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

Solarpower
100 mW
100 mW
Posts: 43
Joined: Nov 28, 2014 7:59 am
Location: Norway

Re: Homemade Battery Packs

Post by Solarpower » Apr 19, 2016 1:25 pm

Got a stupid question here.. Easiest way to test 36V homemade battery pack with no ebike available? 3 12V bulbs in series? No problem with full voltage of 42V?

User avatar
Skalabala
1 kW
1 kW
Posts: 419
Joined: Feb 05, 2014 2:59 pm
Location: South Africa

Re: Homemade Battery Packs

Post by Skalabala » Apr 20, 2016 4:10 am

Solarpower wrote:Got a stupid question here.. Easiest way to test 36V homemade battery pack with no ebike available? 3 12V bulbs in series? No problem with full voltage of 42V?
Yes that will work. Lets say you use 12V bulb from a car, voltage is 14.2+- when engine is running.
Image
Boosted cars are like hot women. A little edgy, every guy wants one, some guys can't handle them, and if you throw a little alcohol in them they'll rock your world! Born a Jap raised as a boer!

User avatar
DrkAngel
10 GW
10 GW
Posts: 4583
Joined: Dec 15, 2010 11:14 am
Location: Upstate-Western-Southern Tier NY. USA

Re: Homemade Battery Packs

Post by DrkAngel » Apr 21, 2016 9:32 am

.
.
. . . . . . . . . . . . . . .
SONY LiPo Mapped!

Building my next battery packs using Sony LiPo.

Image

I decided to precisely map charged capacity at specific voltages ...

Image

These cells look excellent for prolonged usable life by reducing charged voltage!
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

User avatar
Allex
1 GW
1 GW
Posts: 3056
Joined: Dec 05, 2011 8:46 am
Location: Stockholm, Sweden

Re: Homemade Battery Packs

Post by Allex » Apr 27, 2016 12:15 pm

Not home made but a question about P groups.
This is a 15s6p config
Why did they connect all 6 cells on the B- but the rest, like B5 are not connected, I can only see small resistors making the P connection.
If I would want to do a capacity test of each P group I would need connect all those 6 cells together some how. Looks like a PITA.
Attachments
IMG_2402 (1).JPG
IMG_2402 (1).JPG (220.49 KiB) Viewed 2649 times

User avatar
DrkAngel
10 GW
10 GW
Posts: 4583
Joined: Dec 15, 2010 11:14 am
Location: Upstate-Western-Southern Tier NY. USA

Re: Homemade Battery Packs

Post by DrkAngel » Apr 27, 2016 1:22 pm

B+ and B- require full current to controller.
Resistors on the intermediate P require only a minuscule balance current.
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

User avatar
Allex
1 GW
1 GW
Posts: 3056
Joined: Dec 05, 2011 8:46 am
Location: Stockholm, Sweden

Re: Homemade Battery Packs

Post by Allex » Apr 27, 2016 1:33 pm

But if the drain is to high and one cell is bad it wont balance out the cells.
I drained one of those 6 to 2,5V with 10A and rest of them is still 3,33

User avatar
DrkAngel
10 GW
10 GW
Posts: 4583
Joined: Dec 15, 2010 11:14 am
Location: Upstate-Western-Southern Tier NY. USA

Re: Homemade Battery Packs

Post by DrkAngel » Apr 27, 2016 2:19 pm

You could run a heavier balance wire on the pos and neg terminals of that P? ... but highly recommend replacing cell.
One cell better than the rest is much better-safer than one cell worse than the rest!

The resistors allowed diagnosis of poor cell ... seems like a good function!
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There, shallow draughts intoxicate the brain,
And drinking largely, sobers us again.

I enjoy enlightening ... and enlivening the spirit of the innovators.

New & Improved - Acronym Definitions

Index - Homemade Battery Packs - Updated - November 2015

EBike Toolbox - Bargains! $

Endless Sphere Wiki

User avatar
Wheazel
10 kW
10 kW
Posts: 975
Joined: Nov 02, 2010 2:30 pm
Location: Sundsvall, Sweden

Re: Homemade Battery Packs

Post by Wheazel » Apr 27, 2016 3:00 pm

Allex wrote:Not home made but a question about P groups.
This is a 15s6p config
Why did they connect all 6 cells on the B- but the rest, like B5 are not connected, I can only see small resistors making the P connection.
If I would want to do a capacity test of each P group I would need connect all those 6 cells together some how. Looks like a PITA.
What battery is that? I am guessing you are fixing it for a customer?

User avatar
Allex
1 GW
1 GW
Posts: 3056
Joined: Dec 05, 2011 8:46 am
Location: Stockholm, Sweden

Re: Homemade Battery Packs

Post by Allex » Apr 27, 2016 3:57 pm

A friend of mine have a scooter with this one.

DVDRW
100 W
100 W
Posts: 205
Joined: Sep 10, 2012 10:57 am
Location: Tallinn, Estonia, EU
Contact:

Re: Homemade Battery Packs

Post by DVDRW » Apr 28, 2016 3:07 am

Solarpower wrote:Got a stupid question here.. Easiest way to test 36V homemade battery pack with no ebike available? 3 12V bulbs in series? No problem with full voltage of 42V?
Or just long steel wire. Stainless for more resistivity ~50x less than copper.

Will these fuses work with 100V DC?:
https://cache.osta.ee/iv2/auctions/1_9_30576207.jpg
0,5$ each :)

markz
100 GW
100 GW
Posts: 5225
Joined: Jan 09, 2014 11:38 pm
Location: Alberta Canada

Re: Homemade Battery Packs

Post by markz » Apr 28, 2016 4:00 pm

Will these fuses work with 100V DC?:
https://cache.osta.ee/iv2/auctions/1_9_30576207.jpg
0,5$ each :)
I believe they would. I would like to buy some off you if you have a source for them.

Post Reply