Kyle201
10 W
Well alright.
After many delays getting the parts I wanted, and just being busy... I REALLY want to start working on this again, however I'm going to need a lot of help. I'm about hitting the end of my length of knowledge, which is basically just the physical construction aspects... I can't quite wrap my head around how all the wiring is going to work yet.
So here's where I'm at with the build so far:
Here's the wire harness I was sold with my kit. It contains a 40A fuse, is that even enough for a 40A continuous setup??
BMS Diagram which is quite difficult for me to understand. It seems my BMS has two positive and two negative wires? For seperate connections to the battery and also the charger?
BMS itself
Grinfineon 40A Controller and Connectors
Cell Monitor and alarm.. I have 3 of these as they only support 8 cells each. These little units are the most confusing for me, next to the BMS. The support guy from hobbyking told me to get a few sets of those wiring units that came seperately, in order to use all 3 cell monitors? The connector on those wires doesn't seem to attach directly to the cell monitor.. though it can plug to them, there's more pins on the monitor than the wire connector.
I will have to change out at least 3 of my connectors I think. This is an extra sensor connector, the motor is using this, so I will swap the controller's to the same. Now I'm not sure swapping connectors is too difficult.. so, basically just cut the wires behind the connector... strip them back, and then feed them into each of these tiny holes and solder? But which colour wire into which hole is the question... will I have to remove the heat shrink from the motor's to figure out how they should go?? The other connectors seem a little more straight forward.
I also have these bullet connectors which should replace the anderson phase connector on the controller. So basically just solder the wires into the little tunnel at the back of the gold connections? I haven't actually soldered anything in probably 10 years since I did it in school. Soldering seems simple enough, but any soldering or connector swapping tips at all appreciated. I thought there was a third connection I had to change but maybe not.
Motor connections
Okay. And so just some info on my battery setup, I have the 24 cells being split up into 3 packs to distribute. 3 x 4 pack at rear of inner triangle box, 3 x 2 front of triangle and another 3 x 2 pack mounted below the bottom tube. Now I have some diagrams and info on how to set up the battery with the bus bars. But I don't have any examples of something like the 3 x 4 pack so I really have no idea how the bus bars would go on
Bus bars and ring terminals
So the ring terminals will be used to create 'daisy chain' connections between the packs.. and I was given a short length of 10AWG wire for this, is this thick enough for the power? 72v 40A continuous, and I plan to ride down to -20 degrees. Aaaaand... will I need to get a bunch more ring terminals, for each of the BMS to Cell connections? Basically just solder each BMS sense wire to a ring terminal and then sandwhich between bus bars and the bolts?
Bus bar setup
image_6_1.jpg
I was given a set of 12 images and texts to set up the battery which is fairly clear.. however none of the examples really show how the bus bars would work for my largest 4 x 3 battery. Any help there?
Sorry for being so needy on this project, it's just been sitting since I sort of felt a bit overwhelmed by it all. So some clarification to help me wrap my head around all of this will make me very happy!
Thanks again for all the patience and information from everyone here.
After many delays getting the parts I wanted, and just being busy... I REALLY want to start working on this again, however I'm going to need a lot of help. I'm about hitting the end of my length of knowledge, which is basically just the physical construction aspects... I can't quite wrap my head around how all the wiring is going to work yet.
So here's where I'm at with the build so far:
Here's the wire harness I was sold with my kit. It contains a 40A fuse, is that even enough for a 40A continuous setup??
BMS Diagram which is quite difficult for me to understand. It seems my BMS has two positive and two negative wires? For seperate connections to the battery and also the charger?
BMS itself
Grinfineon 40A Controller and Connectors
Cell Monitor and alarm.. I have 3 of these as they only support 8 cells each. These little units are the most confusing for me, next to the BMS. The support guy from hobbyking told me to get a few sets of those wiring units that came seperately, in order to use all 3 cell monitors? The connector on those wires doesn't seem to attach directly to the cell monitor.. though it can plug to them, there's more pins on the monitor than the wire connector.
I will have to change out at least 3 of my connectors I think. This is an extra sensor connector, the motor is using this, so I will swap the controller's to the same. Now I'm not sure swapping connectors is too difficult.. so, basically just cut the wires behind the connector... strip them back, and then feed them into each of these tiny holes and solder? But which colour wire into which hole is the question... will I have to remove the heat shrink from the motor's to figure out how they should go?? The other connectors seem a little more straight forward.
I also have these bullet connectors which should replace the anderson phase connector on the controller. So basically just solder the wires into the little tunnel at the back of the gold connections? I haven't actually soldered anything in probably 10 years since I did it in school. Soldering seems simple enough, but any soldering or connector swapping tips at all appreciated. I thought there was a third connection I had to change but maybe not.
Motor connections
Okay. And so just some info on my battery setup, I have the 24 cells being split up into 3 packs to distribute. 3 x 4 pack at rear of inner triangle box, 3 x 2 front of triangle and another 3 x 2 pack mounted below the bottom tube. Now I have some diagrams and info on how to set up the battery with the bus bars. But I don't have any examples of something like the 3 x 4 pack so I really have no idea how the bus bars would go on
Bus bars and ring terminals
So the ring terminals will be used to create 'daisy chain' connections between the packs.. and I was given a short length of 10AWG wire for this, is this thick enough for the power? 72v 40A continuous, and I plan to ride down to -20 degrees. Aaaaand... will I need to get a bunch more ring terminals, for each of the BMS to Cell connections? Basically just solder each BMS sense wire to a ring terminal and then sandwhich between bus bars and the bolts?
Bus bar setup
image_6_1.jpg
I was given a set of 12 images and texts to set up the battery which is fairly clear.. however none of the examples really show how the bus bars would work for my largest 4 x 3 battery. Any help there?
Sorry for being so needy on this project, it's just been sitting since I sort of felt a bit overwhelmed by it all. So some clarification to help me wrap my head around all of this will make me very happy!
Thanks again for all the patience and information from everyone here.