DIY Battery Packs

1DMF

10 mW
Joined
Nov 15, 2020
Messages
25
Hi,

I'm interested in creating more capacity and volts for my EV's, and was considering buying multiple 24v 7s3p batteries and connecting them parallel and serial to create desired voltage and capacity (AH).

However, these 24v battery starting blocks are 7s3p 28AH 45A continuous 60A peak BMS batteries.

I know the charger seems to paired to series so 7s charger or 13s charger, etc...

Do I need to worry about the 24v BMS or do I need to remove both 24v BMS and series link the batteries to create 48v battery and then add 48v BMS or do I leave the 24v BMS on each pack and then add to the chain a separate 48v BMS?

Sorry if I sound like an idiot, but if it quacks like a duck and waddles like a duck :wink:
 
What is the application, it might not be worth the hassle to make sure the batteries are the same voltage when connecting together all the time you could charge the parallel and series as one or seperate the mess all the time comes with more user mistakes.

1DMF said:
Hi,

I'm interested in creating more capacity and volts for my EV's, and was considering buying multiple 24v 7s3p batteries and connecting them parallel and serial to create desired voltage and capacity (AH).

However, these 24v battery starting blocks are 7s3p 28AH 45A continuous 60A peak BMS batteries.

I know the charger seems to paired to series so 7s charger or 13s charger, etc...

Do I need to worry about the 24v BMS or do I need to remove both 24v BMS and series link the batteries to create 48v battery and then add 48v BMS or do I leave the 24v BMS on each pack and then add to the chain a separate 48v BMS?

Sorry if I sound like an idiot, but if it quacks like a duck and waddles like a duck :wink:
 
1DMF said:
I'm interested in creating more capacity and volts for my EV's, and was considering buying multiple 24v 7s3p batteries and connecting them parallel and serial to create desired voltage and capacity (AH).

However, these 24v battery starting blocks are 7s3p 28AH 45A continuous 60A peak BMS batteries.
I recommend linking the page for those, because a 3p battery that is 28Ah is unusual, unless it uses large format cells. (most people that are doing this type of thing are using 18650-based packs, and there arent' any that have 9.34Ah per cell. ;) )






I know the charger seems to paired to series so 7s charger or 13s charger, etc...
That would be 14s, rather than 13s, if you're seriesing two 7s packs. Then it would technically be a 52v (14s) pack, not a 48v (13s).


Do I need to worry about the 24v BMS or do I need to remove both 24v BMS and series link the batteries to create 48v battery and then add 48v BMS or do I leave the 24v BMS on each pack and then add to the chain a separate 48v BMS?

Check the specs for the FETs on the existing BMSs first.


If you series packs with separate BMSs, then when one BMS shuts off for any reason, the entire pack voltage at that time is now placed across the FETs of the shut-off one. If the FETs are not designed for that voltage, they'll fail. They may fail dramatically, with smoke, and that's fine, because at least you know they failed and can take care of the problem. But they may fail silently, internally shorted, and that means the BMS cannot protect the pack against overcurrent or overdischarge or overtemperature, etc., because it can no longer shut off the discharge port. You won't know anything is wrong until the pack becomes damaged from whatever condition(s) it was trying to prevent. THat might not be immediate; it could take a number of cycles, or even many cycles, and it probably wont' be dramatic.

But there is always the risk of sufficient immediate damage to cause a dramatic failure of the cells, depending on the ocnditions at the time and the reason it tried to shut off).


So, while it has been done with multiple series'd BMSs, the safer route is a single BMS designed to handle the full voltage and current you need out of it...that is also the right one for the specific cell type being used.


Sorry if I sound like an idiot, but if it quacks like a duck and waddles like a duck :wink:
it might be a science experiment by Beaker ;)
 
Thanks for the replies.

I was concerned about this pack, it's 7s3p and meant to be 28AH @ 29.4v (Fijila) bought on eBay.

So based on the calculator I was using https://power-calculation.com/battery-storage-calculator.php

That would require 4.2v max (3.7v nominal) 9900 mah 18650 batteries, which do exist, but that equals @ 30AH.

However, having charged the pack, it's only showing 28.2v so I think I need to send it back as fake or faulty or both.

I did wonder about one BMS failing how it would affect things, so probably best to use single BMS rated for job and remove the others.
 
1DMF said:
I was concerned about this pack, it's 7s3p and meant to be 28AH @ 29.4v (Fijila) bought on eBay.
As previously requested, please provide a link to it, so we can help you with this, and so others can avoid the seller if it turns out they are problematic. (and in the unlikely event they are real and good, so others can buy from them)


That would require 4.2v max (3.7v nominal) 9900 mah 18650 batteries, which do exist, but that equals @ 30AH.
No, they don't exist. You may see them advertised, but they are not real. About 3.5-4Ah-ish is the most you will see in that size battery, for actual real ones. 26650 you might see more, but not 18650.

Higher claims are usually "*fire" cells (ultrafire, trustfire, etc), typically recycled garbage batteries of unknown condition, manufacturer, or specifications, that have been rewrapped with whatever new brand and specs they want to call them. It's possible that the brands themselves do have good real stuff...but it's common to find cells with those names that are fakes.

A possible search to turn up pages about this
https://www.google.com/search?q=fake+18650

However, having charged the pack, it's only showing 28.2v so I think I need to send it back as fake or faulty or both.
No surprise, given the fake cell capacity given.

But there are several reasons a pack may not charge to full voltage.

Cells could be unbalanced; leaving it on the charger long enough (or repeating the charging enough times) will let a properly-functioning balancing BMS fix this.

Charger itself might not be the right output voltage.

Cells could be damaged, so they cannot fully charge.

Cells could be undamaged, but a mix of chemistries (this should never happen, but could if they are recycled random cells, which is not that uncommon in really cheaply made packs (note that actual cost to you for the pack may not be cheap even in these cases, if they are looking for high profits).

Pack-to-BMS may be miswired or damaged connections, so BMS cant' read teh cells and/or balance them, etc.

BMS may be faulty or misprogrammed, so it shuts off charge too soon.

Etc.
 
I took the scooter for a test run and this is definitely a junk battery. I have a 19A 350w (MY1016) scooter, and was replacing 2 x 12v 7000mah SLA batteries coz they only lasted 20 minutes and 4 laps of the park.

This Li-ion battery when I checked this morning was showing 27.8v so it appears to be self-draining from full charge of 28.2 last night. When I went to use the scooter, it had barely any power and got me less than half way round the park, before dying.

The seller link from ebay is here. https://www.ebay.co.uk/itm/255277740335

You are right about some 9900mah being called Ultrafire https://www.ebay.co.uk/itm/334222645471

Is there a reason they put 'fire' in the name :flame: :warn:

I notice there is another make heavily marketed currently (GTF) and wonder if the 'F' also stands for fire!

18650-battery-3-7V-9900mAh-rechargeable-liion-battery-for-Led-flashlight-Torch-batery-litio-battery-Free.jpg_Q90.jpg_.webp


However, I have just found the most amazing 18650 cells available as it is a 19900mah and 7s3p would make a 29v 60AH battery :lol:

Hb48572ddd36a49a1b0c3edf729db7e4fo.jpg


I'm currently in the middle of trying to return the battery for a refund and might just build my own, but to make a 30AH I would need @ 63 batteries as 7s3p @ 3400 mah = 10AH so would need 3 in parallel. I'm a little nervous building my own, as getting it wrong can equal disaster via explosion, fire or electrocution.

Would you recommend Vruzend Solderless kits? or I could make 2 x 12v 3s7p as that is 24AH, which is good enough.

Using these kits...

s-l1600.jpg


I want to be able to run my scooter @ full power for at least an hour, so 2 x 12v 24AH would suffice though that only makes a 26v battery pack, and 29v would give that extra oomph without fully overvolting.

So there are 7s (29.4v) power wall kits I could link up...

s-l1600.jpg


What would you do?
 
Incidentally, while writing the above post, I received a full refund from the seller with the following comment.

It came with a local place that closed down after the lock down in 2020, it was a legit business so i don't believe it's fake, however it has been sitting for a while before the place was liquidated. I will send you a refund now, there is no need to send it back as it appears to be faulty, can i ask that you dispose of it your end. Best Regards Nick

Whether they knew the capacity is fake or not I cannot say, but I received a full refund so can now take a knife to this pack and see how it is made and from what!

Oh there are also 27100 kits
s-l1600.jpg


Which I believe you can get up to 5000mah which would give me a 30AH battery via 7s6p
 
1DMF said:
Incidentally, while writing the above post, I received a full refund from the seller with the following comment.

It came with a local place that closed down after the lock down in 2020, it was a legit business so i don't believe it's fake, however it has been sitting for a while before the place was liquidated. I will send you a refund now, there is no need to send it back as it appears to be faulty, can i ask that you dispose of it your end. Best Regards Nick

Whether they knew the capacity is fake or not I cannot say, but I received a full refund so can now take a knife to this pack and see how it is made and from what!

https://www.youtube.com/watch?v=6_tPaECiAD4

lets see what you find inside yours, maybe you can make a bigger beach. :lol: :lowbatt:
 
1DMF said:
I took the scooter for a test run and this is definitely a junk battery. I have a 19A 350w (MY1016) scooter, and was replacing 2 x 12v 7000mah SLA batteries coz they only lasted 20 minutes and 4 laps of the park.

This Li-ion battery when I checked this morning was showing 27.8v so it appears to be self-draining from full charge of 28.2 last night. When I went to use the scooter, it had barely any power and got me less than half way round the park, before dying.
I'm honestly not surprised at your results.

The seller link from ebay is here. https://www.ebay.co.uk/itm/255277740335
The seller appears to be one of those "random item" types, that probably gets good deals on single items or groups of them, to resell. There's a lot of those on ebay, aliexpress, banggood, amazon, etc. They usually have no idea what anything they sell actually is, so if the info isn't on the label, they can't help (and typically don't care) though there are some exceptions.



Is there a reason they put 'fire' in the name :flame: :warn:
Probably because it sounds "cool" to marketing departments. They do lots of dumb things (worse when they have control over the actual products!).

I notice there is another make heavily marketed currently (GTF) and wonder if the 'F' also stands for fire!
Wouldn't surprise me. ;)


However, I have just found the most amazing 18650 cells available as it is a 19900mah and 7s3p would make a 29v 60AH battery :lol:
If I didn't know that lots of people were being scammed out of their money with them, that would be hilarious. ;)


I'm currently in the middle of trying to return the battery for a refund and might just build my own, but to make a 30AH I would need @ 63 batteries as 7s3p @ 3400 mah = 10AH so would need 3 in parallel. I'm a little nervous building my own, as getting it wrong can equal disaster via explosion, fire or electrocution.
At the low voltage you have, elecrocution is unlikely, but the other two are possibilities with any battery if something goes wrong enough.

What is the physical size of the space you have to install the batteries in? That is the limit on how much you can cram in there.

3.4Ah/cell is realistic with known good grade A new brandname cells from a known good seller. They're likely to cost at least a few dollars each.

Remember, you also want cells that not only have good capacity, but also a high enough "C-rate", meaning how much current they can provide without sagging much in voltage or heating up inside. A typical generic 18650 is a 1C or at best 2C cell; meaning if it's 3.4Ah it can provide 3.4A at 1C, ro 6.8A at 2C, etc. A good one can do a little higher; some will claim very high C-rates (like 30A each cell!) but that is typically only burst, not continuous, and will heat up the cell and cause significant voltage sag while under the load, neither of which you want.

I dont' know what your scooter's motor/controller system specs are, so I don't know how much power you need from the battery; or how you ride, terrain, wind, etc, so I can't do more than guesstimate how many Ah you will need for any specific range.


The SLA only gives you about half the listed capacity, because of the way it works at higher current draws, whereas Lithium will give you most of the listed capacity. So if you had 12Ah SLA, a 6-7Ah Lithium could probably give you the same actual delivered capacity.

SLA can give a lot of current while they're still charged enough to do so even with very small ones, while a too-small LIthium wiht a BMS may sag below the BMS LVC and shutdown.

So, if you use good Li cells, the sag will be less (probably much less) for the same current draw, and you'll need less parallel cells that with cheap ones to get the same power out of the pack, while still getting more range than the SLA.

If your controller is unmodified and has a current limit printed on it, it will help determine how much current your pack must provide to be similar to or better performing than the SLA.

It will also help determine how big the pack must be to provide the range you want.


Would you recommend Vruzend Solderless kits?
I don't have any direct experience with them, but there are threads about them here on the forum.

This list is just any thread that has vruzend anywhere in it
https://endless-sphere.com/forums/search.php?keywords=Vruzend&terms=all&author=&sc=1&sf=all&sr=topics&sk=t&sd=d&st=0&ch=300&t=0&submit=Search
this one is just with it in the title of the thread
https://endless-sphere.com/forums/search.php?keywords=Vruzend&terms=all&author=&sc=1&sf=titleonly&sr=topics&sk=t&sd=d&st=0&ch=300&t=0&submit=Search
and just first posts
https://endless-sphere.com/forums/search.php?keywords=Vruzend&terms=all&author=&sc=1&sf=firstpost&sr=topics&sk=t&sd=d&st=0&ch=300&t=0&submit=Search


Regarding solderless packs in general: If you don't have bumps or vibrations then solderless packs can work alright, but if there is a lot of bumpiness, etc., then connections may be a problem within the pack between cells. Most of these will be momentary issues, but if the pack shape distorts enough it will leave some cells at higher resistance than others, and those cells won't contribute well during higher loads. If any actually become disconnected permanently, the pack loses capacity and puts a higher load on the remaining cells.

There are plenty of other solderless pack discussions, too, including several development threads (like one presently active by APL), that have a lot of good info on problems and solutions. I dont' have any links, but they are mostly in the Battery Technology subforum; the sticky index thread in that section probably has some links.


or I could make 2 x 12v 3s7p as that is 24AH, which is good enough.

Using these kits...

s-l1600.jpg
The image doesn't show everything you would need to make a pack (other than cells); can you link to the actual sale page, so I can see what specifically they don't provide that you'll need, plus info about the BMS, etc., to be sure it would work for you?


I want to be able to run my scooter @ full power for at least an hour, so 2 x 12v 24AH would suffice though that only makes a 26v battery pack, and 29v would give that extra oomph without fully overvolting.

So there are 7s (29.4v) power wall kits I could link up...

s-l1600.jpg
It's likely that powerwalls and the like are designed for relatively steady loads spread over large amounts of cells. An EV, especially with very small batteries, may need to put short high loads on small amounts of cells, so I don't know if the powerwall stuff will do what you want. Without a link to the actual page with all the info (assuming they have it there), I couldn't tell you much about what they use.

I will say that it's likely those cell holders won't hold up under riding conditions; they're only meant to work in a stationary application (and even there, they're not generally good for much outside of a narrow temperature range unless the plastic that keeps compression on them isn't flexible or brittle beyond room temperatures. I would also question the "gold plating" on the terminals; it should prevent corrosion if it's real, but....




What would you do?
Depends on budget, power needs, space constraints, etc. If I had budget and space, I'd probably start with the LiGo packs Grin Tech sells,
https://ebikes.ca/product-info/grin-products/ligo-batteries.html
because they are well-tested, individually protected, environmentally sealed, and designed to be connected together in parallel, etc, and designed for use on things like eskateboards, etc....but they are 36v. (10s1p). So it could require replacing the controller, and/or limiting the throttle mechanically or electricaly so you don't go beyond the original speed / power, or learning to do that manually, to prevent crashes or motor damage from overheating. I don't know how many packs would be required in parallel to provide the power and capacity your scooter needs (i'd guess at least three or four), but they are typically at least $140 each plus shipping (depending on where you live the shipping could add significant cost). Not cheap at all.

If those aren't a possibility, then I'd have be researching what sellers are presently known to be good, and what battery packs are presently known to be good, and get one of those from one of those, that fits within whatever the budget is, and the space constraints of the battery compartment. My general good experiences are with larger sized packs; the smaller ones I've used have all been insufficient for their claimed capabilities.

If budget is too low, you might have to compromise significantly on your expectations, or carry the battery in a backpack with a cable to the scooter (because a cheap enough one that can still do what is needed might be too big for the space available).
 
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