PINNED - ADD ON PACK Step By Step 30ah Pack build / pictures

[Tee]

If I was doing a small add on would I have to buy a PL8 and power source to go with it or is there a cheaper charging set up I could use that would still do a good job charging for me?

[Burgerman]

The answer is probably. But to be sure, we dont really know. Most hobby chargers are garbage... Do unpredictable things, have no PC software so its hard to see whats going on. I would probably buy a pl8 still knowing what I know now.

[Tee]

I thought that was going to be the answer. Just have to save a bit longer. Would much rather wait a while longer and get the correct stuff than get it sooner and ruin it.
Thanks

[Burgerman]

http://www.sinopolybattery.com/main/pro ... =10&ID=367

How can I get 8 of these?

[ex-Gooserider]

By convention, and for maximum safety, it is best practice to look at what ends of the cables are most likely to be 'live' and make those ends FEMALE - as this makes it least likely that you would accidentally short out the connectors. Male D-sub types are less likely than some because the pins are partially protected by the metal rim around the outside, but if you dropped it on something metal with a ridge...

I cringe every time I see one of those XT connectors as they have exposed contacts - only place I'd ever consider using one is to connect something like a motor where I could be positive that the male end could NEVER be 'live' - Note that this is the basic way that AC power cords work - I don't know of ANY code standard that allows exposed live contacts...

As I understand the model stuff, they do try to keep the male ends on stuff that isn't always live, and that the big thing they are worrying about is size and weight, so it is tolerable to take one's chances with a connector that is otherwise sketchy...

This is why I like Andersons, as they are 'genderless' and 'finger-proof' so both ends are always protected 100% - for all intents and purposes there is no way one can short them out by accident, and you'd have to work at it to short one on purpose...

Molex and some of the JST type plugs are almost as good in that they are designed to protect both sets of contacts.

The use of D-subs for this application I think is a bit sketchy, but tolerable in that one can use the female connector on the chair end, since it is always live, and the male charger end is only live if the charger is on and charging - if one makes it a habit to only start charging after making the connection (a good idea in any case) then it is pretty safe and the convenience tradeoff makes it worthwhile...

ex-Gooserider

[expresso]

I went with the XT 90 for a few reasons - but yes the contacts are exposed to start with - heat shrink correctly and they are covered - my main reason for them was its a very tight area and the size and high amps they can hold made them perfect for those reasons -

so far - cant say anything bad about them - they work - there are also some models of XT 90 with an extra tail to them to cover the contacts i believe -

i havnt tried those -

if you can fit Andersons and you can disconnect and connect them easily - then use them - i have yet to find those low force anderson contacts that we discussed some time ago -

[LROBBINS]

The back sides of XT connectors do need protection - heat shrink or caps, but the front sides are protected pretty well from finger contact for both the male and female connectors - the male pins are inside a larger female plastic sleeve so not easily reached. I've not used XT90 but do use a lot of XT30 and some XT60 and they seem among the safest and easiest to use of commonly available connectors.

[expresso]

I first got some XT 60 to use - but never realized how small they are - if anyone wants to use one of these connectors - XT 90 handles the high current up to 120A - 90A Steady - those XT 60 i have i can use for other things maybe one day -

they never concerned me since i heatshrink over it - if its a concern for anyone - you can really use any connector you like - Anderson - XT 90 EC5 - etc, - XT 90 are not expensive either - i happen to like them now that i used them -

i manage to get 10AWG on them - 8 AWG maybe harder - EC 5 may work to handle 8 AWG easier - -

IF anyone is making a ADD ON to leave connected to there chair with LEAD - then you wont have to disconnect it to charge - which you can just use the Anderson and leave it all connected and not worry about it -

XT 90 made it easier for me to be disconnected all the time for charging this ADD ON - only because i have to charge it alone - not connected to my Chair - and charge my chair alone also -

with my other chair with Lead - i dont have to do that and leave it all the time connected - having an Anderson there works fine for me -

Which ever works best - you use - Dont go below 10 AWG to connect to the chair - If using 8 AWG - - may have to use a larger connector thats all

thinking back - maybe i should have used those caps to cover them - i seen them but never considered them - making the connector bigger - i didnt bother - heatshrink so far works for me -

[expresso]

I found these plastic Shoe boxes at the Container Store - its just about perfect size if you use 3 Rows for a 45ah pack which was my first choice - its about 2 inches shorter in lenght than needed - so i got two of them and make it work -

i will duct tape them together and cushion the pack inside - i ended up making 2 Rows 30ah for this one - its enough for me since its going to be connected to my 105ah pack chair -

if you are making a ADD ON to use with Lead and if you can do 3 Rows of 15ah cells for a 45ah pack - its better - this container can fit another row easily and it fits in the Messanger bag i have just right -

cost about 8 dollars for two of them with lids - since i had to extend it - the lid dosnt cover all of it - which is fine since the wiring can stick up the open area -

i am using the same container on my other chair with 3 rows of 12ah cells - 36ah pack and i just stuck it in the bag and left it - this one will be neater when i am done and dont plan on removing it for many many years - -

[Gnomatic]

XT30, XT60, XT90, and SB50 size comparison.



XT30's are tiny!

[shirley_hkg]

Couldn't we have better choices of boxes ?

[shirley_hkg]

---

[Burgerman]

Come with seal? To keep explosion in?

Or:

[expresso]

If you can find a box that suits your needs - and fits - anything can work - the box i found is the best i find around here - closest to the size i need - without trying 40 different stores -

the boxes you show there Shirley would work fine - finding those is another story - if you have a direct link to purchase those boxes - that should work fine -

14 inches long is Min. to fit just right - if 15 inches - i can made it fit in the Bag - 10 inches high is nice to cover the whole Cell and 7 or 8 inches wide for 3 Rows of 15ah cells

i have not been able to find this size online searching google - not sure what i am googling - plastic box ? or Mens plastic shoe box is actually the one i am using - i find many - too large - too short - too wide - -

[expresso]

XT30, XT60, XT90, and SB50 size comparison.



XT30's are tiny!

Huge difference in sizes there - this is the reason for going with the XT 90 - size compact - and ease of connection - but if you can fit the Anderson and it wont be connected and disconnected all the time - what ever works for you -

but i wouldnt go below the XT 90 and 10AWG -

[Gnomatic]

BM would you post a preset for the PL8 for an LiFePO4 24v 8S7P 105Ah pack? Basically a clone of expresso's.


Thank you!

[expresso]

Its Just about done - only left is one cable with anderson end - to go from the ADD ON to the chair - then i can pack it up in my home made plastic shoe box

[expresso]

few more

[expresso]

closer shot

right now its ready to be connected to the PL 8 - and discharge and charge etc, test it - etc, - i will wait till i make the last cable and then do it so i can charge both chairs same day - and then connect them

its not the prettiest - wont win any beatuy contests with my plastic shoe box - but it works and fits perfect in the bag - closed - you never will see it - just use it - get home - flip the bag open on top - you have your charge cable there - you shouldnt have to remove this - if all goes well - if you want to switch chairs - take the Bag its in off the chair and hang it on another chair - as long as you have a Cable made on the other chairs - you just connect them -

[Burgerman]

very very neat!

[expresso]

very very neat!

thanks - its just my plastic shoe box its going in haha - but its going to be a nice fit in there - i would just need to cushion one side alot to fill the gap -

[expresso]

time to eat and have a few shots of something

[Gnomatic]

Pizza looks good.

My pack is coming along, but I must say, you are much better at cable management than I am. Great work!

[Burgerman]

If I were delivering, frank would be added to the pizza and I would collect the tablets.

[expresso]

If I were delivering, frank would be added to the pizza and I would collect the tablets.

..
$17.99 in that bill - is that for ONE Pizza or the whole order on that bill which looks like a few pies ?

well you wont like the price of pizza here in NY thats for sure - unless you get the $1.00 Slice - which sometimes i get a pie from them also - change it up - the Pie i got with Two Cannoli's


https://www.google.com/search?q=cannoli ... q=cannoli+


$26 dollars - cost of everything is out of control here - but the pizza was great

[Burgerman]

For all I think. Frank comes free.

[expresso]

ALL Done - its on the chair - Charged - Discharging now and will recharge again both Chair and ADD ON - NOT Connected - when all done - connect it and that should be it - HOPEFULLY

Its not as Nice looking as i was expecting - the Grey bag is nice - i picked grey this time because black picks up all the dust and you can see it easy -
the bag is a bit bulkier looking on the 646 chair - as it looks on the P222 chair -

its the best i can do - at least Everyone has an idea how its done - i can used to the bag there - the pros - it will give me peace of mind that i can travel as far as i like almost - and not worry about the Main 105ah pack in the chair to get too low - will make it easier on all the Cells - can do easy 50 to 55 Miles and not worry about it - to know for sure - i have to try it one day -

Pros- Everthing -

Cons - its outside the chair

[expresso]

Discharging it -


135Ah Lithium -

[Burgerman]

55 miles is a safe figure. You should still have 6 or 7 left over at that.

But as you say, you don't go that far so the cells get an easy life.

If you were to get a used brushless chair, 8mph (like my new one). It goes 37 miles to a charge stock on lead with about 40 to 45Ah usable from the grp24s...
So with your 135Ah, you would get 135 div by 45 = 3.0. So you would get 3 x 37 miles. Or 111 miles or better... With just a 90Ah lithium, you get 2x the 45Ah so thats still 74+ miles!

Where will it all end Charge every January for some users!

[expresso]

that would be amazing to get 100 miles -- i have to try very hard to do 50 miles - the best i did was 44 miles - and i had the other 36ah ADD ON with me that day to be safe -

the most i did with the 105ah pack was 40 miles - to be safe - and i really think that the Bad Cell i had there was bad from the start - more or less
i dont think 40 miles did it - but who knows -

well see how this works out - i consider it insurance for my 105ah pack - if thats all it does for me - i be very happy this week Thursday - first 90 degree day here - so i be using it first time thursday

Tires coming in next week - thats another little project - - we see how that works out -