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

[expresso]

thats great - now that i think about it - there is one thing i wonder if you have an extra spare - - on my 646se - i have the newer style motors -

i would like a motor hub i think i need - so i can have an adapter made to fit a different rim - do they sell that part alone ? or would you have one - but the motors i am guessing need to be the same ones - not sure if older larger size motors use the same hole spacing hub etc, -

maybe they do - if i am correct - this is what i would need ?

thats from a different quickie chair -

[rustyjames]

I don't have any extra hubs, what I have are attached to motors, but I can give you measurements, if that'll help. I would have to speculate that those hubs are all the same, I'll have to do some research. Do you have a wheel spec on what you plan on using?

[expresso]

no - this is a future project i like to try -

having a hub would be the first step

[expresso]

Charged up - both ADD ON pack and full chair 105ah - connected both and ready to try out first time tomorrow - if it dosnt rain - suppose to be 90 !!!

[Gnomatic]

When you make it to Ohio, let me know. I'll buy you a beer!

[expresso]

When you make it to Ohio, let me know. I'll buy you a beer!

haha - actually now that you said that - i have a few nice cold ones waiting for me when i get back - i dont drink beer that much but ever so often i get the urge for a nice cold one - maybe today is that day - its going to be 90 - this is early for me to get up - i should be out by 10am -

got it ready 135ah -

[expresso]

First day out with the New 30ah pack - connected to my 105ah - was a great day today - i did 39 miles - i went back to the place in NJ i went last year

i met a guy there who works on the Boat Basin there - nice guy - i seen him again - bullshitted for 30 min. and made my way back -

i am charging both of them now - it works great - i Monitor the pack as one 135ah first - then disconnected and monitored each - just to see and looks perfect to me -

39 miles and each cell group reads 3.289v - i left 10 am this morning and got back at 4pm - i can do easy 50 miles now and not worry about any cell groups dropping too low - dont need a cell monitor just more lithium -

[Burgerman]

So 50 miles is easy. Maybe more.

When you monitor, do you check cells on both packs or just one? Because unless all the balance wires on both battery packs are also connected together as you drive, you need to watch both sets seperately.

Likewise, charge each pack seperately, unless you have a Y lead for the balance...

[Burgerman]

But you can do 2 marathons with some left!

Makes you realise that people moaning about getting 9 real world miles of range on the Edge 2 (over on the other channel) are in a different world to us "internet hyperbole" idiots!

[expresso]

its amazing - i am just about done charging up the 30ah pack now - its on CV stage and dropping - about 17Ah was used from the 30ah pack -

i will say the 105Ah pack will be around 75Ah used - at best if not less - i am no where near empty and not worried about it at all without a Cell Monitor

i am not going to do 40 miles a day - thats for sure - one of these days i will shoot for 50 miles just to see for the record -

what i can do if i wanted is connect a Cell monitor to the ADD ON pack - it will give me the Pack Volt only for the whole 135ah - wont give me each cell group for the 105ah pack - only 30ah pack - would need two of them connected to the chair and the ADD ON - i am not going to do that -

dont need it now -

i disconnect the ADD ON and charge on its own - one charger on the Chair - one on the ADD ON - when all done - i will connect the ADD ON again to the chair and thats it - ready for another 50 miles

[expresso]

But you can do 2 marathons with some left!

Makes you realise that people moaning about getting 9 real world miles of range on the Edge 2 (over on the other channel) are in a different world to us "internet hyperbole" idiots!

i have to find some others to convince them to do this - this way i can keep busy in the winter making more packs for others - wont be easy but i can just spread the news -

cant force them - one guy goes about 15 blocks - looses a green - thats it - hes done for the day - One hour outside - cant go anywhere -

i have to say its a trip and a half - next time i may take a bus just up closer to the bridge - not to save battery life - but to take a break

and all the hills i run into - i dont think i will go for the Fastest Bounder chair after i demo it - i feel it already on hills now - i will go for the one below top speed - maybe - if the demo works out good - few more weeks before i go back to demo it

[Burgerman]

cant force them - one guy goes about 15 blocks - looses a green - thats it - hes done for the day - One hour outside - cant go anywhere -

I suspect 90 percent of users never goes more than a mile a day. I already know a few that seldom leave the house, and if they do its maybe monthly.

You and I and a handful of others are different. We use up batteries. I drive, so do not do huge trips in one go. But I still murder batteries on 1 mile of grass airfields up and down all day, or my local town and back for shopping, then another trip to the bank, and later on the pub or for a meal etc. So many smaller trips. And always moving. Even at home, I clean, garden, clean drive, wash van, help neighbors, etc. I certainly cant get a full day from lead in summer. The most I ever go is about 4 or 5 miles and back with lead, and a bit of cleaning, shopping, and you are done! All lights out. I have been on a few stupidly long dog walks with lithium though. Mostly because you just can. And STILL go into town in the evening for a few hours without that range/battery light anxiety.

This sort of heavy use had another downside...



This is 3 years! The Wheelchair Services gave up on me. Theres 2 more in the workshop...

When the LA were providing my lead batteries they were in despair. I was eating a set every 6 to 8 months. They just didn't get it. Most of their users were happy with batteries after 4 to 6 years! They WERE knackered too, but they never go far enough to know it.

[expresso]

i cant go back to lead now -

here is the graphs for the 30ah ADD ON - i do notice Cell group 1 is a bit weaker than the rest - i will keep an eye on it - but not going to do anything just yet
as a unit 135ah together - they work perfect together - this ADD ON turned out to be insurance for my 105ah pack -

at first i was suppose to make a 45ah pack and use it on the Lead Chair - and use the 36ah from the lead chair for the 105ah pack - that was first intention - before that i was going to use this ADD On on the next Chair i get thinking i will get lead anyway and have the ADD ON ready for that chair -

i didnt get a new chair yet - so have to time to figure that one out later -with any luck - i may just get the bounder with lithium - in case i dont get lithium on my next chair - i will use one of the ADD ON packs from the start with any new chair i get if it has Lead -

[expresso]

new charging station -

[Burgerman]

6mV difference is just 6 one thousandths of one volt!

Its this much of the 3.3V cell:

0.006V
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3.300V
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0000000000000000000000000000000000000000000000000000000000000000000000000000 (3300)

[expresso]

which means nothing then - i wasnt going to sweat this one - my main concern is the 105ah in the chair - i am slowly getting used to it - and not worry so fast when i see the lines not all in order -

[Burgerman]

If you want to fix it, charge again, but set termination to the lowest it will go (5 or 10mA?) and allow the low cell to soak at 3.600v for a longer time, up to an hour or two. It may not turn off, so set a temporary CV limit of 2 or 4 hours. till it catches up.

Then monitor. Or discharge for a couple of Ah.

[expresso]

i leave it alone for now - i already shut the charger off etc, - next time i will set it lower and see - its at 100mah now i think -

[Burgerman]

its amazing - i am just about done charging up the 30ah pack now - its on CV stage and dropping - about 17Ah was used from the 30ah pack -

10% less than 2/3rds...

i will say the 105Ah pack will be around 75Ah used - at best if not less - i am no where near empty and not worried about it at all without a Cell Monitor

Will be the same under 2/3rds, say 65 Ah.

i am not going to do 40 miles a day - thats for sure - one of these days i will shoot for 50 miles just to see for the record -

You will get that other third, with some left. So 60 miles and a few over.

[expresso]

your right - its just about done and its 63Ah used - wont be more than 65Ah when done - CV stage and dropping now

this is great - i can do 50 easy and not worry about a low cell group at all - i bet money on it -

[expresso]

done - looks perfect to me - and 65ah returned - very nice - i will keep the ADD On all the time on this chair -

[shirley_hkg]

You are peerless !

Sadly , another lonesome wolf .

[expresso]

Did you mean Fearless ? And yes lonesome for real - no one can ride with me now - i offered suggestions - over a year ago when i first made the first ADD ON -

i suggested - Save some money - and by this time - there be enough to get a ADD ON also - i could do the work - - didnt work out - of course he didnt listen -

i will find a victim soon to bring him or her over to lithium -

[Burgerman]

Do you like how I can tell you how many Ah you would return?

[shirley_hkg]

YES . WE LOVE TO !

[Burgerman]

You are peerless !

Sadly , another lonesome wolf .

He means you have no peers!

WiKi...

In society
An equal in age, education, or social class, as in peer group or social peer-to-peer processes

Means you are on your own!

[expresso]

i see - its not easy getting others to do what i am doing
its something you want to do or else forget it - there are many risks - time - effort - money - but if willing to take them - the rewards are great

[Burgerman]

I agree. You are at the cutting edge. Experimenting. You are using equipment like hobby chargers never intended for this job, relatively cheap Chinese cells, and everything needs monitoring and possible maintenance. You know how now. So it doesn't scare you. So to you the risk and pain if it goes wrong are worth it. Most people dont want the problems, and just want plug and play and someone to blame. And the same benefits without the effort!

[expresso]

yes i agree and i was one of them also had no choice but to go all in and make it work - took awhile to cross over - i had to make sure i had a better than 50% chance of making it work - as it itched closer and closer - as things came together - i visioned it working - just a matter of doing what it takes -

one tool at a time - i still need help everytime i have to remove it or do something - so i hope i did a good job this time and wont have to touch it again for A While

by Adding this ADD ON - its a huge difference now - i dont worry about ever getting too low on the Cells - as long as the charge graphs still the same as now - should be fine -

now its the tires i have to deal with

[Dan]

I'm thinking of building an add on pack.
Do the little cell holders clip together?
http://www.evassemble.com/index.php?mai ... cts_id=155

Just making sure these are the correct cells.
Headway 40152S 15ah LiFePO4 Cell -screw tab
http://www.evassemble.com/index.php?mai ... cts_id=175