No wiring diagram, need assistance for 48V configuration

[machmike]

Hi everyone,

I am configuring a 48v battery circuit for an e-bike. The manufacturer did not include a wiring diagram. I took some pictures showing the batteries and the wires provided.
Assistance would be greatly appreciated. It goes into a Diggler E-scooter. so the batteries have to be lined up as shown

There are 4 12v 12AH batteries which are to be placed in a line (as shown - can be flipped 180 so connectors are closer)
There are 2x short negative wires
There is 1x positive wire
the charger/power converter wires. The negative wire is the longest, the positive much shorter.

I need wiring description in simple terms

Here are the pictures.

picture 1 batteries and connector wires

Picture 2
Charger/power converter connections.

From left to right we can call the batteries A, B, C, D
I understand I may need to move some of the batteries 180 so the connectors are close enough for the wires.


I appreciate the help
Mike

 

[Ypedal]

Welcome to ES !

Just go + from one batt to - of the next one then + of the 2nd batt to - of the 3rd one.. etc.. this leaves you with one - and one + at each end.. ie: 48v.

Filament tape, duct tape, packing tape, double sided foam mounting tape, etc.. try to secure the bricks to eachother so they don't wiggle around and make the connectors come loose.. even better is to solder the connectors on the battery tabs if you are handy with that.

Keep those babies charged at all times.. you canot charge too often with SLA.. 5 minute test run up the street.. charge them again.. etc.. 8)

 

[deardancer3]

wear safety glasses and work on a non-conductive surface.

Each battery has a plus and a minus.

You will be conecting the plus from battery 1 to the minus of battery 2.
the plus from battery 2 goes to the minus to battery 3.
the plus from battery 3 goes to the minus of battery 4.

the minus from battery one is the minus of the pack.
the plus from batttery 4 is the plus of the pack. conect a fuse to here and the other end of the fuse wire to the plus of the load. this is the 48volt output of the pack

you connect the charger wires to the 48v battery output pins.

 

[machmike]

I will mock wire it and see if I understood you correctly.
It's funny how nervouse you get when tinkering with something new to you. I can build a classic 1969 mach-1 mustang from the frame up...but an e-scooter freaks me out.

Ok here is my mock up. Please tell me if I have managed to be 'challenged' enough to have not put your words into proper visual form.

Question 1
Now I would have thought the colored wires might have meant something?
As you can see these batteries are snug so they aren't moving anywhere. The system is running a Crystalite Phoenix motor. - It should go 30+mph.

 

[Rassy]

Welcome to the forum Mike. You got good advice from experts and your illustration looks correct. At this point, since the wire colors that connect the batteries don't mean anything, I like to put a small wrap of red tape on the end of any non-red wire that attaches to a positive post, and a small wrap of black tape on the end of any non-black wire that attaches to a negative post. This may seem like extra work if you don't expect to ever take it apart again, but most of us end up playing with multiple projects and then end of switching batteries around for reasons only known to fellow e-bikers.

Edit: Also, you do not need to hook up the batteries in a row as you have shown, which makes the negative wire to the controller have a long ways to go. One alternative would be to jump past battery B to battery C (- to +), then battery C to battery D, then battery D to battery B. That way the + and - to the controller start near each other. You may need to flip some batteries 180 degrees as you mentioned earlier (such as batteries B, C, and D), so that all the wires will reach. Now, if you have already color coded the wire ends, this change will be easier to make.

 

[machmike]

This configuration would be optimal for power and efficiency correct? :|

Mike

 

[Rassy]

This configuration would be optimal for power and efficiency correct?

Don't really know what you are asking. The only way to hook up four batteries for 48V is in series. It makes no difference how the four batteries are lined up or turned as long as the + of each battery is hooked to the - of another battery (except the extreme end + and - that go to the controller). Of course you must be careful not to let cables flop around and touch each others ends or the wrong terminals or you will get burned. Those extreme end + and - posts are just like the posts of your car battery, but much worse at 48 volts, so don't ever short between them.