Integrated Battery switching??? (2 batteries)

Because I'd also read of many complications as well and I'm just learning all this. It seemed too much maintenance. I'm open if it's dunce proof. But I've no info on the two original 48V batteries that came with the bikes and neither company has it or is willing to supply it so I'm coming in handicapped. I also ride top speed non-stop for the full charge more often than not, through the rough with one, pavement the other, so I'm trying to touch my limits but within the parameters of keeping everything worry and hassle free. I'm riding for fun more than commuting.
Well, completely separated batteries you switch between with a toggle (or whatever) are "simpler" than figuring out the batteries or dealing with plugging / unplugging for charge / discharge stuff is probably closer to "dunce proof". ;)

If the "battery combiners" out there were correctly documented for what they actually are internally, instead of so many made-up things to make them sound better for marketing, I'd recommend using one of those. A simple "ideal diode" setup would work, and some of them probably are that. But some are supposedly "smart" and without knowing the actual internals and the actual specific logic used, behavior can't be predicted and thus safety can't be guaranteed.

So...if you use a simple DP3T (2P3T, On-Off-On) toggle switch rated for *at minimum* the max possible current your system will ever draw under worst case conditions, then it's pretty safe and foolproof. Sometimes these are called DP2T or 2P2T center-off instead, since the center throw has no contacts some manufacturers dont' count it, which makes it confusing.

You use a double pole so that you can switch *both* negative and positive wires, completely isolating the battery not being used at the moment.

You use a triple throw so it has three positions, using center as off. That way no possible normal failure of the switch can cause both batteries to be connected together at any time.

The common contact of each pole of the switch goes to your controller / system input, one for + and one for -.

Then the corresponding poles for each outside throw go to the + and - of each battery. If the switch has poles for the center throw, leave them unconnected.


All Grin: 600C Display --> SuperHarness --> PhaseRunner V6 --> Bafang G62 750W 6.5T. Also connected to the Superharness is the PAS, throttle and rear brake, no lights and front brake yet. I haven't a Cycle Analyst. I can't use the programming jack on the cable either and I'm gleaning that's a driver issue. Superharness' Troubleshooting points toward changing a setting to address my speedometer dropping out but I think it's outdated as it doesn't tell you how and where. But it doesn't mention my milage difference of about 15% so I'm struggling. This doesn't exactly match their instructions so I'd hoped for a response from Grin before changing things.

If the speed sensing is being done via something other than a motor hall sensor, then under some conditions the PR can swtich to reading the hall sensor instead, and that will screw up the speed and mileage readings because the hall will have many times more pulses per rotation than the typical wheelspeed sensor, as the motor hall will be reading at least a few dozen more poles / magnets.
 
Seems I spoke too soon. Searching for a 60A DP3T produces limited results. Is everyone using the same marine grade rotary cam switches? Is a 60A switch indeed what I need for this 48V / 8.4 high discharge Frame Bag Battery?
 
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Seems I spoke too soon. Searching for a 60A DP3T produces limited results. Is everyone using the same marine grade rotary cam switches? Is a 60A switch indeed what I need for this 48V / 8.4 high discharge Frame Bag Battery?
Doesnt' matter what the battery is, current-wise.

What matters is how much current your system will ever draw, worst case, under the worst case riding conditions, etc.

So you need a switch that can handle *at least* that much current, and *at least* the voltage your system uses maximum at full charge.

Whatever numbers those are, are the *minimums* for what the switch must be rated for.

There are plenty of large switches that will handle the current, but you must verify they will also handle the voltage. If they don't, then the contacts can weld during turn-on or turn-off (as long as you aren't running anything during turn off it won't be an issue, but turn-on still can be as it charges your controller caps, though the risk is minimal).

You can add a precharge circuit to each switch input to it's common to prevent the arcing that causes the welding. There are many threads and posts about precharge for ways to do it, including one using a battery cutoff switch where a resistor was embedded into it.


Basically what you need is already described in this thread on the first page in various ways.


If you can't find a switch to do it, you can use a tiny switch to control a relay or contactor to do it.
 
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