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:
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/Pr ... 7b8daff5cc
Zephyr 4.1b LiPO 24s components order form: http://www.mouser.com/ProjectManager/Pr ... d4c8fbb68a
The new 4.4b board
Extreme close up: http://www.zenid.com/images/GF4.1b.jpg
BOM parts list: http://www.zenid.com/docs/Zephyr%20LiPo ... -v4.4a.doc
Assembly, test & operating instructions: https://endless-sphere.com/forums/downlo ... ?id=132445
Fechter/Goodrum/Hecker BMS Thread on ES (lots of discussion about building and testing the unit)
https://endless-sphere.com/forums/viewto ... 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):