Fechter Goodrum "Zephyr" v4.4b BMS/LVC boards - IN STOCK!

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Fechter Goodrum "Zephyr" v4.4b BMS/LVC boards - IN STOCK!

Postby Zenid » Wed Nov 13, 2013 12:29 am

Since Richard and Gary made the sad decision to shelf further development of their famed BMS "Zephyr" units, there have been quite a few enquiries about these through my shop, posts on ES, and elsewhere. I blogged quite extensively about building and wiring this up, testing it, and - more recently - about wiring up and testing the built-in cell-level LVC throttle pass-through and alarm system. It seems a shame to have such an excellent, well-documented and rugged unit languishing in virtual nonexistence, so, with the agreement of Richard Fechter, I've freed the design from its ExpressPCB format, and had some made up locally for cheaper. We've agreed that once I reach break-even point, a chunk of the profits will go to the board's designers.

[Edit 2014-08-27]: The 4.4b boards are now in stock and available here:
http://www.zenid.com/goodrumfechter.htm

The 4.4b version of the boards has had a change incorporated to add protection for higher voltage arrangements. A soldermask has been added and component labels and values have been tidied up and moved to the silkscreen layer, where they're easier to read. Square pads have been added for the capacitors, and holes for jump-wires between banks are included.

The boards have been priced affordably, and are perfect for any EV DIY enthusiast or electronic hobbyist. I have introduced a price break on international shipping, and discounts for multiple items.

Mouser project component order forms are below, currently for the 24s component lists. I'm pretty sure the component form items are all correct, but I would advise checking against the BOM document (see 'more resources' below) before ordering, just to make sure. [Edit: 2014-12-13: Order form 'tested' and one error found: Rx07-(1kΩ) quantity now corrected (thanks, marcexec!)]

Zephyr 4.1b LiFePO4 24s components order form:
http://www.mouser.com/ProjectManager/ProjectDetail.aspx?AccessID=7b8daff5cc
Zephyr 4.1b LiPO 24s components order form: http://www.mouser.com/ProjectManager/ProjectDetail.aspx?AccessID=d4c8fbb68a

Image
The new 4.4b board
Extreme close up: http://www.zenid.com/images/GF4.1b.jpg

More resources:

BOM parts list: http://www.zenid.com/docs/Zephyr%20LiPo-LiFePO4%20BMS%20BOM-v4.4a.doc
Assembly, test & operating instructions: http://endless-sphere.com/forums/download/file.php?id=132445

Fechter/Goodrum/Hecker BMS Thread on ES (lots of discussion about building and testing the unit)
viewtopic.php?f=14&t=26554

Blog Guide(1): Building the “Zephyr” BMS Circuit Board
http://zenid10.wordpress.com/2011/08/28 ... uit-board/

Blog Guide(2): Wiring and assembling the Zephyr BMS
http://zenid10.wordpress.com/2011/08/28 ... -bms-unit/

Blog Guide(3): Low Voltage Cutoff & Alarm System (Zephyr BMS)
http://zenid10.wordpress.com/2013/09/29 ... rm-system/

Here are some pictures of my build from start to finish (on one of the earlier boards, without silkscreen/soldermask):
Image
Image
Image
Image
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby alternety » Wed Nov 13, 2013 2:38 am

Perhaps you could find someone on the thread in the US to also make boards under the same sort of agreements with the designers. If you share compatible artwork it could be sold in the US at a reasonable price (less international shipping).
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby Zenid » Wed Nov 13, 2013 2:49 am

alternety wrote:Perhaps you could find someone on the thread in the US to also make boards under the same sort of agreements with the designers. If you share compatible artwork it could be sold in the US at a reasonable price (less international shipping).

Unfortunately I'm the only person who's paid to have any made up and the UK is where I'm based. From what I gather, Richard is quite happy to share the design with anyone who wants to do this, locally, - perhaps you'd like the job... :)

Even taking into account the $10 surplus, they still work out quite a bit cheaper than before because I got a much better deal. The one I originally bought cost about $110 and that was sharing postage with someone else from the UK!
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby dmwahl » Wed Nov 13, 2013 4:28 pm

I'd be happy to at least quote production of these for US distribution. I'm in Wisconsin, so pretty close to the middle of the US.
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby cal3thousand » Wed Nov 13, 2013 6:09 pm

This is very interesting indeed. Are there example builds anywhere here?
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby Zenid » Wed Nov 13, 2013 7:28 pm

cal3thousand wrote:This is very interesting indeed. Are there example builds anywhere here?

Yes. In those links I put in the first post under "more resources". Two detail my build in my blog, and one is to the ES "Zephyr" thread, which has hundreds of posts about the board, testing etc.!
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby Zenid » Wed Nov 13, 2013 9:23 pm

dmwahl wrote:I'd be happy to at least quote production of these for US distribution. I'm in Wisconsin, so pretty close to the middle of the US.

The boards I had made are 12.15" x 5.225" (308.61mm x 132.72mm) two-layer, 1.6mm thick board, HASL (lead-free) surface, and silk screen but no solder mask. I got charged for having more than 2 "boards" on one sheet (there's the main board and the two end-plates for 16/24 cell respectively). Maybe you could get a quote for a run of 20.
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby scriewy » Thu Nov 14, 2013 8:20 pm

Hooot DAAAAMN !........!....

it's alive !

very good inititive, unlike "execute order 66" like they did in starwars o.O and everybody die


if i remember correctly these can be choped every 8 chanals, so could be cool if there were ready 4 holes in corners of every segment so people that dont want or cant go around with 30cm board can chop and stack them ontop of eachother with raising scriews like used in PC chasis to fix the motherboard in air without shorting all the pins to chasis.

on users part will be left to chop and shove it in some custom box and maybe add a fan for those that will add higher watt resistors to balance faster.

or maybe you can offer choped versions with time.

now that i think, i guess some 1 probably mentioned that in main development thread
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby Zenid » Fri Nov 15, 2013 12:55 pm

scriewy wrote:Hooot DAAAAMN !........!....
if i remember correctly these can be choped every 8 chanals, so could be cool if there were ready 4 holes in corners of every segment so people that dont want or cant go around with 30cm board can chop and stack them ontop of eachother with raising scriews like used in PC chasis to fix the motherboard in air without shorting all the pins to chasis.

When this batch sells out, you may have your holes! Not too big, though. There are 17 [Edit 29/11/2013: 12 remaining] (out of 20) boards left in this batch, but I have no idea how long it will take for them to sell.

I'd also like to add small wire-holes so that the first of each 8-cell circuit bank can have it's first negative cell rail connected to the
last rail of the one before, either by jumpers, or by little jump-wires like I did on mine. That way, you'll only need 24 wires instead of that awkward 27. It's practically impossible to get any connectors above 24/25 pin, in my experience, and so losing those three wires makes it perfect for a 24-pin ATX connector, as I did with mine. For my PCB, I had to drill little holes to do this like so (see the little black jump wires):
http://zenid10.files.wordpress.com/2011 ... 0x1200.jpg

I think two more holes in the end-plates for alarm connections might come in handy too. One for LVC and the other for HVC.
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby Zenid » Tue Jan 07, 2014 11:16 am

Just a heads up: 11 remaining!
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby Zenid » Mon Jan 13, 2014 6:44 am

10 left.
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby Zenid » Wed Jan 15, 2014 6:44 pm

9...
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby Zenid » Fri Jan 17, 2014 6:47 am

7...
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby Zenid » Tue Feb 18, 2014 7:27 am

6...
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby trevc2 » Wed Feb 19, 2014 8:12 pm

So... what's the ballpark figure for how much through-hole soldering this thing takes to complete? How many holes? Just trying to gauge how long it would take for assembly/testing.

Close to pulling the trigger. ;)

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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby Zenid » Fri Feb 21, 2014 2:56 am

trevc2 wrote:So... what's the ballpark figure for how much through-hole soldering this thing takes to complete? How many holes? Just trying to gauge how long it would take for assembly/testing.

Close to pulling the trigger. ;)

It depends how fast you are at soldering :)

I never counted the holes, but you can see them in the image below:
http://zenid10.files.wordpress.com/2011/08/gf02-st2-16-1600x1200.jpg

I did it for a few hours each weekend for a month, but some people seem to be able to get them finished a lot faster. Ask 2007blueprius, I think he had his done in a single weekend.

Oh, and by the way there's FIVE left now. So if you're going to pull the trigger, best do it while there's still a round left in the chamber ;)
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby ahedproductions » Wed Mar 12, 2014 4:30 am

Hello Zenid!
I'm building a two-motor e-bike monster and I've decided to give it a 16S pack of 40Ah Winston Battery cells. The FGv4 looks great for it! Are there any left? And I have a question about the charger - please recommend, if you know any good ones! I think a 10A charger will be fine, but I have no idea which ones are fine with the FGv4.
**************
- Custom made steel tubing bike frame with a fork from a lightweight motorcycle -
- 16S 40Ah WB-LYP40AHA LiFeYPO4 -
- 2 Conhismotor 1kW motors with an automatic (PIC16F88) delta-star switchover @ about 50km/h (gets me to about 90km/h on flat ground) -
- 2 EB215 controllers with improvements (e-brake, cruise control, programming, caps, etc.) -
- GT Power meter with remote shunt mod -
- 20-72V - 12V DC/DC (like the ones in your webshop) -
- A full array of LED head, rear and turning lights with their own DC/DC CC controllers -
Left todo - BMS, charger!
**************
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby marcexec » Wed Mar 12, 2014 4:57 am

Welcome to the forum Bill!
viewtopic.php?f=14&t=26554&p=426397&hilit=dumb#p426397 should answer your question - this is "just" the for sale thread for one batch (sorry Zenid :), quite happy with the product and delivery BTW).

Please post you build here somewhere, maybe viewforum.php?f=12 ?
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby ahedproductions » Thu Mar 13, 2014 2:37 am

marcexec wrote:Welcome to the forum Bill!
viewtopic.php?f=14&t=26554&p=426397&hilit=dumb#p426397 should answer your question - this is "just" the for sale thread for one batch (sorry Zenid :), quite happy with the product and delivery BTW).

Please post you build here somewhere, maybe viewforum.php?f=12 ?
90km/h is a motorcycle IMO ;)

Thanks! Question answered, sorry I hijacked the thread. :) Still piling up parts, will post pictures as I start "dressing" up the frame.
Good luck!
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Re: Fechter Goodrum v4.4a BMS/LVC boards in stock!

Postby Zenid » Thu Mar 13, 2014 2:56 am

ahedproductions wrote:The FGv4 looks great for it! Are there any left? And I have a question about the charger - please recommend, if you know any good ones! I think a 10A charger will be fine, but I have no idea which ones are fine with the FGv4.

Yes. There are now THREE of the FGv4 boards left. As for a charger there's a post on my blog all about the charger I use with my own 24s 'Zephyr':
http://zenid10.wordpress.com/2013/09/08/emc-ya-later/

See also the sections on Building and wiring the unit.
http://zenid10.wordpress.com/category/4-how-to-guide/4-7-lithium-upgrade/4-7-2-building-the-goodrum-fechter-zephyr-bms/4-7-2-1-building-the-zephyr-circuit-board/
http://zenid10.wordpress.com/category/4-how-to-guide/4-7-lithium-upgrade/4-7-2-building-the-goodrum-fechter-zephyr-bms/4-7-2-3-wiring-and-assembling-the-zephyr-bms-unit/

[ADMINS: Feel free to move these posts somewhere else if you want to keep everything all tidy and on-topic.]
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Re: Fechter Goodrum v4.4b BMS/LVC boards [PRE-ORDERS]

Postby Zenid » Thu Jun 12, 2014 2:14 pm

Just an update. I'm having more enquiries from people who missed out on the last batch of GF 4.4 boards. I'm now accepting pre-orders for a batch of 4.4b boards. Once I have 6 pre-orders, I order the batch. The pre-orders will not include shipping - that will be taken care of when the boards are available and ready to ship.

The 4.4b is not functionally different from the 4.4a. But:

1) Square pads have been added for the 47K capacitors, to prevent further confusion about which way round they go
2) Holes have been added to enable jump-wires to be soldered to save on redundant wiring where the top cell of one bank meeting the bottom cell of the next. This allows a 24-pin connector to used for a 24s circuit, and so on
3) The component labels and values have been tidied up and moved to the silkscreen layer, where they're easier to read.
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Re: Fechter Goodrum v4.4b BMS/LVC boards [PRE-ORDERS]

Postby Zenid » Sun Jul 13, 2014 3:19 pm

5 more pre-orders now needed before the next run of boards (4.4b).
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Re: Fechter Goodrum v4.4b BMS/LVC boards [PRE-ORDERS]

Postby dmwahl » Thu Jul 24, 2014 11:22 am

Could you provide a link to the most recent version of the schematic, searching for it through all the posts regarding these would be pretty time consuming.
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Re: Fechter Goodrum v4.4b BMS/LVC boards [PRE-ORDERS]

Postby Zenid » Tue Jul 29, 2014 10:16 am

dmwahl wrote:Could you provide a link to the most recent version of the schematic, searching for it through all the posts regarding these would be pretty time consuming.


Here you are.

Zephyr 4.4 schematic corrected.jpg

Zephyr 4.4 schematic corrected Sheet 2.jpg
(80.64 KiB) Downloaded 4 times
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Re: Fechter Goodrum v4.4b BMS/LVC boards [PRE-ORDERS]

Postby Zenid » Tue Jul 29, 2014 10:18 am

THREE more pre-orders now needed before the next run of boards (4.4b).
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