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  1. N

    Copper Bus-bar

    Fantastic! Just wondering, once I get the area in squared mm for my copper bar, do I look for wire-current charts with single stranded copper or multi strands? Single stranded right? Since the copper bar is just one big strand really?
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    Copper Bus-bar

    I don't quite get you. The two packs are being made out of around 184 cells which will individually be spot welding to nickel strips. Our plan was to drill holes in the copper bus-bars and then attach lugs like this onto the end of the wires (by a hydraulic crimper) and then use a 6mm screw...
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    Copper Bus-bar

    Hey there, We're making a 13s14p battery composed of a 6s14p pack and a 7s14p pack. After doing some rough calculations, we think that we need two copper bus-bars capable of carrying a peak of 150A current in each with a nominal of 50A each at all times. It's for an electric go-kart. We're...
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    ME0909 Screw Size

    UPDATE: It's M8 (i.e 7.9mm terminals)
  5. N

    ME0909 Screw Size

    Hey, Just wondering if anyone knew what size the terminals are on the ME0909 (i.e what mm holed lugs should I buy?) The datasheet doesn't say/in chinese Datasheet: https://sep.yimg.com/ty/cdn/yhst-129399866319704/ME0909.pdf?t=1523318830&
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    Determining Wire Gauge

    Not really.
  7. N

    Determining Wire Gauge

    https://www.ebay.co.uk/itm/25mm2-Black-Red-110-A-Amps-Flexible-PVC-Battery-Welding-Cable-FREE-LUG-PER-METRE/192371086353 Do these seem okay?
  8. N

    Determining Wire Gauge

    The hardware has no lugs on it. I'll be buying lugs depending on what wire gauge I buy. There's a big price difference between 2/0 and 4. I'd prefer to buy 4 AWG but I need to know if it's capable of handling that 300A for 30 seconds and if it won't melt before my fuse trips at 400A. I can't...
  9. N

    Determining Wire Gauge

    The longest single wire piece is 1.5m and thats connecting battery + to motor (its not a full loop length - just one segment of wire). Alright, so 2 AWG vs 4 AWG? Which one? I'm using this fuse: http://kellycontroller.com/ane-400a-fuse-p-199.html Would the 400A fuse be okay? The wiring won't...
  10. N

    Determining Wire Gauge

    Hey, I'm running a 48V battery to my ME0909 motor and KDZ48401 controller. Continious current draw is 100A and peak draw is 300A for 30 seconds. My longest wire length is approximately 1.5m (from battery+ to one motor connection). I also have a 400A fuse. It's for an electric go-kart...
  11. N

    How to connect wire to battery busbar

    Ah. I'm using a 70mm2 lug for my 2/0 AWG wire which is 68mm2. This one to be precise https://www.ebay.co.uk/itm/Copper-Tube-Terminals-Battery-Starter-Cable-Lugs-Eyelets-Tags-Crimp-70mm-Cable-/191926498818 I'll just crimp the 2/0 AWG wire on one end and screw in the other end onto the bus bar...
  12. N

    Choosing Ground

    Perfect. Thank you all.
  13. N

    Choosing Ground

    Secondary battery is for powering the controller at 18V and also for switching the coils on the main contactor on/off. Right so - I'll keep the two batteries in their own loops then without touching the chassis frame. What's the reason behind not connecting negative terminals to the chassis...
  14. N

    Choosing Ground

    Hey, We're building an electric go-kart with a 48V main battery and 18V secondary battery. We have an old go-kart chassis with a metal core structure. I'm just wondering - is there a need to connect the negative terminals of the batteries to the chassis metal frame?
  15. N

    How to connect wire to battery busbar

    Oh. Are those just standard lugs? As in, can I just crimp the wire to one end and then drill a hole on the bus bar to mount the flat side of the lug?
  16. N

    How to connect wire to battery busbar

    Hi, We're in the process of assembling around 195 18650 cells in order to power our ME0909 PMDC motor at 48V. It's rated for 100A continious and 300A for 30 seconds. Our cells will be joined together by massive bus bars and there will be two main bus bars - each being able to carry 150A...
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    Wiring Help

    Update: Think it was just a language barrier. I clarified with them and got the an OK to this It's okay if I use it like this. - In normal situation, close key switch, close kill switch, drive. - In normal situation, come to complete stop, open kill switch, open key switch. (or open key...
  18. N

    Wiring Help

    Okay. During my e-mails with Kelly Controllers about the different states, I e-mailed them the latest schematic(attached) with the kill switch in series with the key switch and the replied saying "During the motor is running,please don't operate both kill switch and key switch." I asked them to...
  19. N

    Wiring Help

    Got a reply from Kelly Controllers for any future readers "Yes,if PWR key switch is turned off and controller is not getting power,you can enable kill switch" I'm still going to go with the all switches in series in the latest diagram.
  20. N

    Wiring Help

    Fantastic! First of all, I cannot thank you (and everyone else) enough for the amount of help you guys have provided. I would literally still be staring at those diagrams without the help I received. Absolutely amazing. I cannot wait to see this thing move. I'll keep you posted with any updates...
  21. N

    Wiring Help

    Thanks for the reply. I'll give you some context about the usage. It's a student project. Our batteries are going to give us a run-time of 20-30minutes. Our main use case is just in an isolated racing track in the day-time with supervision at all times - no lights, no LED's on the kart. Just a...
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    Wiring Help

    Haven't gotten a reply yet but I just had a thought. In this diagram If the controller key switch is turned off, wouldn't that mean the kill switch won't have 18V to keep the 12V main contactor on which will shut it off. And thus - you can never have the traction battery on with controller...
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    Wiring Help

    Fantastic! How do you guys know so much.. I guess I'll need to wait for Kelly controllers to reply until II can order parts (just in case I have to resort to single battery - that'll mean I'll need the 48V contactor as part of the order)
  24. N

    Wiring Help

    Sent the e-mail. Will let you know when they reply. Thanks for all the help. There are so many things in this that I would have never considered. One last thing - I'm planning on getting the KDZ48401 with regen. support but at the moment, my go-kart has a standard mechanical brake. Is it okay...
  25. N

    Wiring Help

    Yes, I meant if the brake was pressed really hard, it would disable the controller. When I was talking about a main switch to trigger the cotnactor I meant the kill switch - my bad sorry. In the diagram you provided, isn't it possible to have controller power but kill switch off? If I do go...
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