BMS Channel Wires Question.

[kilowatt]

I separated my cammy_CC 36 volt 20 Amp LifePo4 into two blocks to put into panniers and I need to extend the BMS channel wires. I have already made the power buss. The BMS will be in the rack trunk and the BMS has two channel wire connections (one 8 pin and one 4 pin (12 channels)).

Do I need to reconnect the wires to the battery in the same order or are all 12 channels independent? They are all labeled and ready to go but not sure about this last configuration.

Cammy has been great responding to my questions but just doesn't understand this one. Any help would be great.

Dave

 

[Icewrench]

Keep those channel wires in the same order as before.

 

[kilowatt]

Thanks, that was my intent if I didn't get an answer. I had to be real careful removing the duct tape from the battery as I lifted several spot welds and needed to break out the big solder gun. This is turning out to be a very ambitious project but will be well worth it in the end. Thanks again.

Dave

 

[docnjoj]

Hi Killowatt. Do you have any pictures as I am going to attempt similar surgery on my 48 volt 20 ah Ping. Thanks in advance.
otherDoc

 

[kilowatt]

Otherdoc,

Yes, I can take some pictures this weekend. I purchased two tupperware cases that I am fitting the battery halves into and its looking like it will work very well. I sent an email to Cammy_CC asking for a pinout of the BMS 8 and 4 pin connectors just to make sure I haven't miswired a channel but I think I'm ok. The battery is floating at 44.8 volts so that looks good. My battery was a big block and too big to sit behind my seat on the rack when I saw a post on Ampbikes showing the pannier idea so that inspired me. I was a bit worried about jumping into this project but started last weekend. Scary!

When I removed the first layers of tape I found a cardboard wrap and then more tape. I lifted some weld spots removing the tape so be careful but I found some weld joints lose that I knew I didn't cause so I checked every cell and soldered the lose ones. When you have all the tape off you will have two blocks that fold away from each other into two series connected 6S19P (36v 20amp for me). I ran 10g buss wires between the two and had to extend the + and - wires and BMS channel wires to make the side by side pannier run. When I finished the wiring I left the cells exposed and only strategically wrapped the battery with electrical tape. I used shock foam around the battery and put soft foam in the bottom of the pannier. The tupperware cases are air and water tight. I install a rubber gromet in the case and then filled it with silicon. I want to be able to quickly expose the cells for any future problems or reconfigure the battery again.

On top of the panniers I have a bike trunk that houses the controller and BMS. Plenty of room for tools, etc. Its going to be a busy Thanksgiving weekend so I'll try to "carve" out some time to take the pics. "Carve" Ha!

Dave

 

[docnjoj]

Thanks kilowatt! I posted a thread to show the beginning of my surgery. Ping really does a good job of making it easy to open his batteries. No duct tape directly on the top but separation with cardstock. I didn't even pull a wire off!
Here is the thread:
http://endless-sphere.com/forums/viewtopic.php?f=14&t=14414
otherdoc