Switch between parallel and series quickly

sophocha

10 mW
Joined
Jun 30, 2016
Messages
22
Alright guys, I'm totally happy with my ebike setup using 15 multistar batteries in series to up the voltage to 84v but when I try to charge everything I have to unplug all the batteries and use three parallel boards which take quite some time. Is there an elegant way of using switches to switch from series to parallel quickly? I don't want to use a BMS and cut all the wires, I like the fact that my ISDT charger can balance each individual cell (sometimes I use three 8A ISDT chargers for each pack which reduce the charging time to two hours)

Thanks
 

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You'd need a lot of switches, and if you accidentally leave one in the wrong position while switching another one, KAPOW.

And first you have to switch them all to their "disconnected" positions, before you can switch any of them to the other mode from what they had been before.

Same thing with relays, except that at least that would be automatic. However, relays can disconnect or bounce under vibration, and if this happens under load, it could arc and destroy the relay if it isn't rated to handle that. (normally you wouldn't need to rate such relays very high, because you never need to switch them under load)

it's much much easier to use a plug to switch configurations. You'd need one with as many pins as you ahve packs and cell interconnects, if you want to balance this way.

You'd use larger pins/plugs for the main pack terminals that get seriesed, and smaller for the balance wires as thse don't normally see any significant current.

The seriesing one is a small plug, as it only has to jumper between the packs to put them in series. If you like you can also parallel balance connectors of the appropriate packs if it's higher than a 1p pack.

The paralleling one would be a bit bigger becuase it would also have the wires on it that go out to the charger.

This has been done in various ways by others, but I can't think of what search terms would find those threads easily. :(
 
Maybe Amberwolf was thinking of a seriesing or paralleling block plug arrangement something like the one pictured here:

dogman dan reviews Icecube57's Lipo battery harness review. 4 battery set.
https://endless-sphere.com/forums/viewtopic.php?f=4&t=32096

except yours will be a 15 battery set, 3 rows of 5 4s bricks? And maybe XT connectors could be ganged together like in the video below?

[youtube]kCHrkdo3YDQ[/youtube]
 
I like this idea! I will use it in the future for sure, much more convenient...

mark5 said:
Maybe Amberwolf was thinking of a seriesing or paralleling block plug arrangement something like the one pictured here:

dogman dan reviews Icecube57's Lipo battery harness review. 4 battery set.
https://endless-sphere.com/forums/viewtopic.php?f=4&t=32096

except yours will be a 15 battery set, 3 rows of 5 4s bricks? And maybe XT connectors could be ganged together like in the video below?

[youtube]kCHrkdo3YDQ[/youtube]
 
That sounds dangerous, so I;m not going to attempt it :)

amberwolf said:
You'd need a lot of switches, and if you accidentally leave one in the wrong position while switching another one, KAPOW.

And first you have to switch them all to their "disconnected" positions, before you can switch any of them to the other mode from what they had been before.

Same thing with relays, except that at least that would be automatic. However, relays can disconnect or bounce under vibration, and if this happens under load, it could arc and destroy the relay if it isn't rated to handle that. (normally you wouldn't need to rate such relays very high, because you never need to switch them under load)

it's much much easier to use a plug to switch configurations. You'd need one with as many pins as you ahve packs and cell interconnects, if you want to balance this way.

You'd use larger pins/plugs for the main pack terminals that get seriesed, and smaller for the balance wires as thse don't normally see any significant current.

The seriesing one is a small plug, as it only has to jumper between the packs to put them in series. If you like you can also parallel balance connectors of the appropriate packs if it's higher than a 1p pack.

The paralleling one would be a bit bigger becuase it would also have the wires on it that go out to the charger.

This has been done in various ways by others, but I can't think of what search terms would find those threads easily. :(
 
I forgot that icecube578 already had built series/parallel XT connecting harnesses. In his videos, see how easy it is to switch between series and parallel:

New V2 XT90 Series Parallel Harness Simplifying Ebike Charging
[youtube]2w2NHkDx1N4[/youtube]

Update to XT90 Harness. Glued To One Plug Configuration
[youtube]ZLULxkeGUC4[/youtube]

Another improvement on the One Plug Series Parallel Harness
[youtube]EML6wuC_Z8s[/youtube]
 
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