Assembled Hi-Power LiPo battery packs - any interest?

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Another big order going in for high power cells!

Postby jonescg » Tue Feb 07, 2017 7:37 am

Shout out to Aussie Hi-Power electric projects!

Another big order will be going in for these 5000 mAh, 30C/60C pouch cells from FEP. The cost price landed is $16 per cell. If you want me to build a battery for you I can do that too - the final cost ends up being about $1.12 per Wh, for a built pack with no BMS or enclosure, give or take a little.

I have commitment for at least 500 cells, but would like to get this order over 1000 if possible - this should lower the unit price a bit too.

Hope to place the order very soon (in the next 2 weeks) so get in touch!

Chris
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Re: Assembled Hi-Power LiPo battery packs - any interest?

Postby jonescg » Mon Feb 13, 2017 8:58 am

Just finished a little nugget for a pretty cool EV Challenge bike:

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20170212_151813.jpg
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I've ordered more PCBs and copper, and a cell order is going in at the end of the week. Let me know if you're in!

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Re: Assembled Hi-Power LiPo battery packs - any interest?

Postby jonescg » Fri Feb 17, 2017 7:38 am

Hey guys, last chance - I'm placing the order on Monday. Getting a few extras while I can, but if you want more chime in.
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Re: Assembled Hi-Power LiPo battery packs - any interest?

Postby jonescg » Sun Feb 19, 2017 9:23 am

Been busy in the shed lately.

16s3p with BMUs.jpg
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This little pack is 16s3p (60 volts, 15 Ah), which is likely to be sold shortly. I have also got a 14s3p pack on the way (48 volts, 15 Ah). The battery monitoring modules are the same ones used on Voltron. All they do is monitor cells. If a cell goes out of spec the normally conducting loop goes open circuit so you can use this to release a relay which is indicating green/red up on the dash, or sound a buzzer. This particular battery also has hole spacings on the insulating board to suit the ZEVA BMS modules. Unfortunately you need two modules as they only go up to 12s, so space is tight.

Edit - this battery is sold :)
16s3p pack done.jpg
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New kit is on its way!
Last edited by jonescg on Fri Feb 24, 2017 7:26 am, edited 1 time in total. View post history.
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Re: Assembled Hi-Power LiPo battery packs - any interest?

Postby jmetric » Sat Mar 04, 2017 12:49 am

you wrote:If a cell goes out of spec the normally conducting loop goes open circuit so you can use this to release a relay which is indicating green/red up on the dash, or sound a buzzer.

Voltron, I would like to build a simple top balancer or really a top discharger. I would like to set a setting or hardwire in a voltage like 4.100V and have a unit that
when the pack is full it would slowly drain all the cells down to 4.10V
this little board can trigger a relay, so I suppose it could trigger a relay on that cell to put it across something like a 4watt resistor?

Can you see that working with that system?

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Re: Assembled Hi-Power LiPo battery packs - any interest?

Postby jonescg » Sat Mar 04, 2017 4:45 am

jmetric wrote:you wrote:If a cell goes out of spec the normally conducting loop goes open circuit so you can use this to release a relay which is indicating green/red up on the dash, or sound a buzzer.

Voltron, I would like to build a simple top balancer or really a top discharger. I would like to set a setting or hardwire in a voltage like 4.100V and have a unit that
when the pack is full it would slowly drain all the cells down to 4.10V
this little board can trigger a relay, so I suppose it could trigger a relay on that cell to put it across something like a 4watt resistor?

Can you see that working with that system?

John Metric


Sounds a lot like a balancing BMS... :) Rod is working on a Version 3 of this BMS, and it will feature a 50 mA shunt current. Even ZEVA's BMS does this already, but it requires a CAN interface to get it to do things. Part of the appeal of this BMS is the simplicity - very analogue. However the lack of balancing is a bit annoying.

You can get the tripped relay to even put a resistor in series with the throttle so you have turtle mode - again, a rather analogue way of doing it but effective. If you wanted it to enable a relay which put a load across the high cell, you would need a means to turn it off when it got to 4.1 V.
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Re: Assembled Hi-Power LiPo battery packs - any interest?

Postby jonescg » Sun Mar 05, 2017 3:41 am

Hi all,

I just finished this little 20s2p (74 V, 10 Ah) battery. It's capable of 200 amps continuous (20 C) and the manufacturer claims 60 C burst. I melt 8 gauge wiring at 20 C so I don't see a lot of point in testing it any harder. The enclosure is made of 3 mm clear polycarbonate and the cells are held in place with polyurethane adhesive. If a cell should ever bomb out, which I am confident won't happen due to the vetting process I put it through, the cells are replaceable thanks to the screw termination system. You will spend all day doing it though. This adhesive is sturdy stuff.

I can put any connector you like on it, likewise charging leads can be managed via the terminals with ring-lugs. The balance ports are Molex 2.54 mm pitch connectors, 10 each. This battery doesn't come with a BMS, but you can easily solder the new BMS wire harness to the existing wires to make it work. Bear in mind the space inside is 10 mm deep, so it would want to be a fairly compact BMS.

Outside dimensions are (LxWxH) 189 mm x 106 mm x 164 mm, weight is 5.8 kg complete.

It is for sale - $950 plus shipping anywhere in Australia (Austpost will come to about $60 I think).

20s2p pack complete2.jpg
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20s2p pack complete.jpg
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Re: Assembled Hi-Power LiPo battery packs - any interest?

Postby Rube » Mon Mar 06, 2017 4:35 am

Awesome, so much power in such a small form factor. Like all of you batteries I wish my current setup could accommodate the dimensions. Lesson for the next build. Are the enclosure bolts M1?
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Re: Assembled Hi-Power LiPo battery packs - any interest?

Postby jonescg » Mon Mar 06, 2017 8:06 am

Rube wrote:Awesome, so much power in such a small form factor. Like all of you batteries I wish my current setup could accommodate the dimensions. Lesson for the next build. Are the enclosure bolts M1?


M3. The end plates are 4.5 mm thick, so they take a thread very well.

There are other ways to put them together, but this is by far the easiest and most convenient layout.
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Re: Assembled Hi-Power LiPo battery packs - any interest?

Postby jonescg » Mon Mar 20, 2017 7:52 pm

Quick bump to let folks know I will have a good 80-odd cells spare form the last order, so I have enough cells to build a 1.5 kWh pack.

Here is a nice compact and powerful 22s4p pack I just finished.

22s4p on balance.jpg
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I'm still working on the BMS. It uses the NC loop but said NC loop needs a 12 V supply. I bought a 7W DC DC converter so some fiddling will be required to get it to work. Otherwise it's ready to go. It will just fit inside one of SamD's frames.
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Re: Assembled Hi-Power LiPo battery packs - any interest?

Postby Rube » Tue Mar 21, 2017 4:10 am

Regarding dimensions a quick look at the first post indicates these cell are:
- 145mm height (withconnectors)
- 50mm width
- 20.7mm thickness/ cell (approx)
Is that about right?
Add min 3mm per side to these dimensions for Lexan enclosure?
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Re: Assembled Hi-Power LiPo battery packs - any interest?

Postby jonescg » Tue Mar 21, 2017 6:59 am

Yes these cells are 8.2 mm thick, 50 mm wide and 135 mm long, up to the tabs. A built pack will fit inside an enclosure measuring 100 mm wide, 158 mm high and as long as your capacity and voltage dictate. The 158 high means there is a comfortable 10 mm for a BMS on top.
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Re: Assembled Hi-Power LiPo battery packs - any interest?

Postby Rube » Wed Mar 22, 2017 5:21 am

Thanks Chris, I'm interested in configuring these into a 52V pack to power a tangent drive for the next project. Off the top of my head that would be 14S/3P.
Need to check available space.
When you say 100mm wide enclosure I'm thinking you mean cells side by side?
Thanks for your help.
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Re: Assembled Hi-Power LiPo battery packs - any interest?

Postby boytitan » Wed Mar 22, 2017 9:06 am

How small would a 52v 8ah pack be ?
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Re: Assembled Hi-Power LiPo battery packs - any interest?

Postby jonescg » Wed Mar 22, 2017 8:34 pm

Yes the inside dimensions would need to be 100 mm wide and 158 mm tall.

Because I use 3 mm polycarbonate sides and 4.5 mm endplates, the final dimensions end up being 106 mm wide, 164 mm tall, and (8.2 x (s/2) x p + 9) mm long, where s and p refer to series and parallel requirements.

Boytitan, The closest I can get for you is a 10 Ah pack. 14s2p complete with enclosure (but no BMS) is about $700.
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