1clue said:
What size battery packs are you maniacs using now?
I understand 12s to get 48 volts. How big are the cells you're buying and what sort of range do you get?
Matt's blog site is a little bit unclear, he says he's using 6s2p LiPo to get 48v, but it would really be 12s1p. And the 10 AH would technically be 10,000 mAh, and I don't think think the cells I saw could do that.
I'm trying to anticipate battery pack size and charging needs. So I would like to hear from you guys, to find out what you do.
I anticipate using this thing every available day for a 40 mile round trip, so I would like it to be as foolproof as possible.
I also want advice on a charger.
Thanks.
Matt, and some others here, are using 6s-5000mAh LiPo packs from HobbyCity (in HK...) and other such places. Using four of these, 2 in series and 2 in parallel will give you 12s2p and 10Ah. Each LiPo cell is 3.7V "nominal", which is what the voltage settles down to after the surface charge burns off in a few seconds. That means a 12s setup is really only 44.4V, not 48V. These cells need to be charged to 4.2V per cell, so fresh off the charger a 12s configuration will be at 50.4V. By comparison, SLA cells have a nominal voltage of 2V and a charge voltage of 2.40-2.45V, so a 24-cell SLA configuration will have a nominal voltage of 48.0V, and would get charged to 58.8V.
LiFePO4-based cells, like the powerful a123s, have a bit lower nominal voltage, at 3.3V, and get charged to about 3.65-3.70V. For charging purposes, 4 LiFePO4 cells can replace 6 SLAs, so a 16s LiFePO4 setup has an optimum charge voltage of 58.4V, which is about the same as a 48V SLA configuration. One big performance advantage of doing a "drop-in" LiFePO4 replacement in a system designed for SLAs is that the system has to be capable of handling the voltage of the pack right off the charger, so for a 48V SLA setup, that means 58.8V. Once under any sort of load, the voltage will quickly drop to the nominal voltage of 48V. A 16s LiFePO4 setup will also start out at 58V, or so, right off the charger, but the nominal voltage for a 16s setup is 52.8V, a full 4V higher than the 48V SLA nominal pack voltage. Anyway, there are lots of 48V SLA charging solutions, most of which will work for a 16s LiFePO4 setup.
One still unknown issue with using typical "HV" RC controllers is that most are designed to work with a max of 12s LiPo setups. In particular, the Castle Creations HV110 is the prefered unit for these ebike setups right now, but it is not clear to me, at least, how much higher than 50V they can handle. I know from my RC helicopter experience that a 15s a123 setup works just fine, but I'm not sure about 16s just yet. I plan on testing an HV85 I have this week, to see. A 15s pack gets charged to about 55V, so I know it is good to that point, but a few more volts, I'm just not sure about yet.
LiPo packs save weight over most LiFePO4 setups, and can supply tons of current. They are not exactly the safest solution though, as they can catch fire if overcharged, or over-discharged. With proper precautions, however, they can work quite well. Not sure about how long they will last, however. Not too long ago, even good LiPo packs would only last a year, or so, but now, I just don't know. We'll find out soon enough,I'm guessing, as several people here have been using them for awhile now.
Personally, on my own bikes, I only use a123-based packs. With these RC-based setups, I'm hoping to standardize all my setups for 16s configurations. I just finished building a new 16s5p 48V/11.5Ah a123 pack, using the good cells out of a bunch of reject DeWalt tool packs that I bought from Doc.
-- Gary