A123 AMP20M1HD-A Battery pack kit

Today had some good work on my cargo bike. Also have made little jig, to solder brass nuts to my kit's PCB:
20130311_152457

Jig allows to solder one 32S board or variation of smaller boards.
I will use soldering paste and then place it on my vacuum former to get all soldered nicely, at least i am hopping so:
20130311_174002

i have fitted thermostat to control temp a bit.
 
You sir are one classy engineer! It looks like I'm gunna have to order another 12S kit! Very impressive.
otherDoc
 
docnjoj said:
You sir are one classy engineer! It looks like I'm gunna have to order another 12S kit! Very impressive.
otherDoc
Click to expand...
Thanks. Just looks to me that its harder and harder to get these cells. i hope Wanxiang will kick in with new cells coming of the line some time in near future.
Hows your battery doing? Is everything alright with the kit? No defects that you noticed i should know about?
Regards
 
agniusm said:
docnjoj said:
You sir are one classy engineer! It looks like I'm gunna have to order another 12S kit! Very impressive.
otherDoc
Click to expand...
Thanks. Just looks to me that its harder and harder to get these cells. i hope Wanxiang will kick in with new cells coming of the line some time in near future.
Hows your battery doing? Is everything alright with the kit? No defects that you noticed i should know about?
Regards
Click to expand...
Nope! The battery is doing fine but my Hyperion charger died and went back to the dealer.I have been bulk charging with Cellogs as the cut off for about a week until they either fix it or replace it. Prolly replace. Your kit is still going like gangbusters.
otherDoc
 
This is good to hear about the battery. My iCharger died after working on one pack and had no chance on changing it. Have balance charger but i cant discharge cells with info on AH.
 
I don't trust those fancy charger D/C data. I still use the method dnmun showed which is a couple of electric heaters or food warmers and a Wattmeter and Celllogs for LVC.
otherDoc
 
Don't know who you asking but me, charging to 3.65V and then discharging to 2.0V as per spec. I het 19.6AH mostly, as per spec few at 19.3AH rest 20AH+
 
I'm a bit more conservative in that I charge to 3.59 and D/C to about 2.7. I usually get 17-18 amp hours from my 20 amp cells but since I only use about 12-13 ah it is all good. The Hyperion takes forever to do this ( it only D/C at 1 amp) but can automatically do C/DC cycles up to 5 in a row I believe. I will test again when I get it back. there is a way to increase the D/C rate by using a car battery for the D/C but I havent tried that yet.
otherDoc
 
what 'c' rate are you guys using to determine 18 to 20ahr capacity i.e. how many amps discharge
 
when charging through the balance connectors with the bc168 charger i miss charging 2 of the cells in my 16s pack..
it is the cells that lie between the balance connectors with the + terminal on one connector and a - terminal on the other connector..
i was wondering if it was possible to fix this..
12s.JPG
its only the 12s one but the green line is what im wanting so that charging through the balance connectors would work..
it would charge the first 6 cells then swap to the lower balance connector to charge the last 6 cells..

cheers adrian
 
Just make harness:

Kit JST
7 way JST for 6S http://www.hobbyking.com/hobbyking/store/__9739__JST_XH_Wire_Extension_6S_20cm_10pcs_bag_.html
1 - BC168 1
2 - BC168 2
3 - BC168 3
4 - BC168 4
5 - BC168 5
6 - BC168 6
7 - BC168 7 +BC168 1 (solder 1st 6S JST connector wire 7 with 2nd 6S JST conector wire 1 to kits plug pin 7)
7 way JST for 6s http://www.hobbyking.com/hobbyking/store/__9739__JST_XH_Wire_Extension_6S_20cm_10pcs_bag_.html
7 - BC168 2
8 - BC168 3
9 - BC168 4
10 - BC168 5
11 - BC168 6
12 - BC168 7 + BC168 1 (solder 2nd 6S JST connector wire 7 with 1st 4S JST conector wire 1 to kits plug pin 12)
5 way JST for 4S http://www.hobbyking.com/hobbyking/store/__9737__JST_XH_4S_Wire_Extension_20cm_10pcs_bag_.html
13 - BC168 2
14 - BC168 3
15 - BC168 4
16 - BC168 5
17 - BC168 6
Check my thinking as i am tired today :)
 
I screwed up several of the balance traces in the first kit I built. I made a harnass from a 6S EPBuddy balance wire set and it works fine. At first I tried to jumper the burnt trace but it worked better with the harnass soldered to a small ring and screwed into one of the block screws. Got close to 100 cycles on it and it works fine (as long as you don't try to charge with a Hyperion 1420 charger!) Sorry my personal grudge! Bulk charging and a Thunder 12 20 work fine! I'll bet the BC168 works fine too. It will be my next charger!
otherdoc
 
Great Work! now ready for 15kW :twisted:

I noticed you seem to have installed what look like kapton tape on the side of each cells?

Doc
 
Doctorbass said:
Great Work! now ready for 15kW :twisted:

I noticed you seem to have installed what look like kapton tape on the side of each cells?

Doc
Click to expand...

Yes, kapton it was. that will isolate cell from cell somewhat. I used it to tape off some minor marks on cells as well.
 
Finally got around to catch up with you guys and use my own kit on my bike rather old prototype. Here are some photos of the battery that i like very much myself as it turned out good:
20130531_130745

20130531_130749

20130531_140455

20130531_163016

20130531_171456

20130531_171748

Here is comparison between old prototype and new:
IMAG0076

20130531_173118
 
Thanks found it :)

Are fiberglass sheet the best for battery case in term of weight and protection? Maybe I should do the same and get this one:
http://www.ebay.co.uk/itm/3mm-Fibreglass-16-X-3-GRP-sheet-Limo-Banger-Saloon-stox-chassis-Mardave-car-/290949795364?pt=UK_ToysGames_RadioControlled_JN&hash=item43bdf58e24
 
Update. If someone who bought a kit from me need replacement pins for balance connectors they are cheap on eBay:
http://www.ebay.com/itm/100-pcs-VH-...210?pt=LH_DefaultDomain_0&hash=item5ae1310e7a
..and if soldering is not your first thing, here is the crimper:
http://www.ebay.com/itm/SN-28B-Dupo...934?pt=LH_DefaultDomain_0&hash=item19e099bc0e
If you need connector housings just do a search on 3.96mm on eBay:
http://www.ebay.com/sch/i.html?_odk...l1313.TR0.TRC0.X3.96mm+&_nkw=3.96mm+&_sacat=0

To further simplify they are called JST VHR connectors. digi-key has them, probably most will.

I will add some info later to easily upgrade your rev. 1 kits with better battery poles including bullet connectors, some copper, cutting, drilling, soldering involved :)
 
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