Battery ADD on pack - First Attempt -

[expresso]

You know if my Math is correct - i figure out that it does seem as it will fit in the Battery Tray itself - i may not have to do anything else - then i can slide the tray out or in easily and it wont move around - very good - 15ah size - i am starting to feel that may be best choice at lease for my chair -

if i ever get to this point - i have to figure out how best to add the charging cable - the way i have it now - its not ideal - but it works - only opening is in the front - just thinking ahead - - this is why i hate the winter - too much time home - making me just think - and drink


this would be the pack - 6 x 8 - same way - i am not referring to how its connected - - just the way its build - this would be the same way with the 15ah Cells - i think i like it this way better - so the orange tabs sticking out would be on the bottom and top of the pack to keep it safe - instead of sideways -

[Scollard]

You know if my Math is correct - i figure out that it does seem as it will fit in the Battery Tray itself - i may not have to do anything else - then i can slide the tray out or in easily and it wont move around - very good - 15ah size - i am starting to feel that may be best choice at lease for my chair -

if i ever get to this point - i have to figure out how best to add the charging cable - the way i have it now - its not ideal - but it works - only opening is in the front - just thinking ahead - - this is why i hate the winter - too much time home - making me just think - and drink


this would be the pack - 6 x 8 - same way - i am not referring to how its connected - - just the way its build - this would be the same way with the 15ah Cells - i think i like it this way better - so the orange tabs sticking out would be on the bottom and top of the pack to keep it safe - instead of sideways -

That is exactly the shape it would be. The connectivity would be different. It would connect something like this:

Connection is easy. You just hookup your BMS, if you haven't finally come over the the Hobby Charger side, use an anderson connector to the battery and an anderson connector to the chair.

[Burgerman]

Here's one I made earlier. 80 12Ah cells, split into 2 packs, for easy lifting of uneven size and obscure shape to allow some parts to be 7 cells deep while others are 5...

120Ah and still 50lb lighter than a couple of lead bricks.

Looks odd. Fits great. Will allow HUGE range and uses up space wasted under the seat to the millimetre.

[expresso]

Yes i like that idea Scollard -- Very good - thanks - that will help me alot when the time comes - and the size will be i believe perfect with those 15ah Cells- i really feel it can fit in the battery tray itself which i wanted - to keep it neat and the same way as before -

i think i get to do the whole chair - i will most likely go the hobby charger way - doing the balance cable is another issue - that will be harder than doing this pack from your Picture - its perfect -

one big pack - one set of cables going to my Chair anderson which is a Black one - so i would have to use a Black anderson on the battery end also - ? and then a balance charge cable for me to use -

BM - thats very nice - you are able to work the space you have to the max -

in my case - this pack with the 15ah cells will be my max space - i hope i have a little room on top for wires and to slide it out at least -

[expresso]

That is exactly the shape it would be. The connectivity would be different. It would connect something like this:

24V battery.jpg

Connection is easy. You just hookup your BMS, if you haven't finally come over the the Hobby Charger side, use an anderson connector to the battery and an anderson connector to the chair.[/quote]


would you be able to make a picture with the Balance wires in there correct locations also ? no rush - when ever since this is future project i look forward to - with this kind of help - i can do it -

[expresso]

Here's one I made earlier. 80 12Ah cells, split into 2 packs, for easy lifting of uneven size and obscure shape to allow some parts to be 7 cells deep while others are 5...

120Ah and still 50lb lighter than a couple of lead bricks.

Looks odd. Fits great. Will allow HUGE range and uses up space wasted under the seat to the millimetre.

810_1173.JPG

Nice - your lucky you are able to do all this and know what your doing at the same time

[Scollard]

Yes i like that idea Scollard -- Very good - thanks - that will help me alot when the time comes - and the size will be i believe perfect with those 15ah Cells- i really feel it can fit in the battery tray itself which i wanted - to keep it neat and the same way as before -

i think i get to do the whole chair - i will most likely go the hobby charger way - doing the balance cable is another issue - that will be harder than doing this pack from your Picture - its perfect -

one big pack - one set of cables going to my Chair anderson which is a Black one - so i would have to use a Black anderson on the battery end also - ? and then a balance charge cable for me to use -

BM - thats very nice - you are able to work the space you have to the max -

in my case - this pack with the 15ah cells will be my max space - i hope i have a little room on top for wires and to slide it out at least -

Wires are not a problem. They can run in the channels left by the feet of the orange blocks. You also don't have to rubberize the back of the battery box because only the plastic orange block can touch the chair. You might want to put a rubber top on the battery similar to the one you put on the bottom of the battery tray. That is what I'm doing for my packs. Once you go Hobby Charger, cables are simplified. You will have 1 cable that will terminate in an Anderson Connector that plugs into the Chair. And you will have one consisting of 2 charge wires followed by 9 balance wires that all terminate in a single Combo Sub-D plug. Then you just need a charge cable, almost identical to the one from the battery,for the PL8 to the chair.

[Scollard]

would you be able to make a picture with the Balance wires in there correct locations also ? no rush - when ever since this is future project i look forward to - with this kind of help - i can do it -

Don't worry about the balance wires just yet. When we build your add on pack you will understand. The only difference between the add on pack and this full chair pack will be instead of 2 rows there will be 6 rows. The connectivity is going to be identical.

I'm assuming that for your add on pack you are going to go with a 2x8 cell configuration. We can also build a 4x4 if you want.

You have 8 orange blocks right now. You can convince yourself that a 6x8 pack will fit into your other chair by making a 6 wide 8 deep template. Just knock together 3 side by side for the width and then 3 side by side for the other edge and then 1 at 90˚ to finish 8 deep. That only uses 7 blocks.

[expresso]

The ADD ON - i will make 2 rolls of 8 cells - that way it will fit in my backpack - the length is just about a inch longer than the charger i carry in there now - so that should be fine - and Two rolls is not bad - if it fits good - and i can another roll later on - i will get another 8 cells and add them - that should be more than enough for a ADD ON to work good the whole day out in the summer - plus i already have the correct lay out to make it this way - Picture perfect and just have to do the balance wires which i would need help to be sure about where they go also -

the other chair is going to be the full pack - but the 15ah Cells are a little larger battery - the blocks are 85mm x 43mm - instead of 80mm x 40mm - with out my helper - i cant do anything anyway - even if i have the rest of my Cells -

dont know why its taking so long this time to get my order shipped - making me think maybe i need to find another place to buy them for next order - instead of EV -

i have a few batteries Grp24 MK - sitting so i just put 4 of my cells near it to see that it fits - with out the blocks on - but still i can see that its going to work that way - at least it looks that way - the height is good for sure and have a little space on top - i like having that room for the wires and not have to worry about it being so tight fitting on top

i am curious either way - how the 12ah 72 cells would fit - and the 15ah cells - i want to do it once and thats it - i be very surprised if the 12ah Cells fit 6 high - but never know once i try it - but the 15ah version - looks very good and will fit -
may be a tight fit with the blocks attached to fit in the tray - but that may be a good thing also - so it wont move around -

[expresso]

Scollard -

what kind of Rubber Mat do you use to cover the top of the battery pack ? if all goes well with the 15ah cells - they may fit right in the tray i have - i wont need to add rubber on the bottom - but i would like to do that to the top if i have that extra room there -

i would try to find those rubber caps that BM used to cover each both also - i like that idea and besides looking neat - it double insurance - i may even add the rubber mat on to anyway -

this is why i picked the winter to do this - i dont have to really rush - i still would like to have all the parts to start - but i am in no rush - i should have this going by the summer for sure - at least by March -

the full chair - that i will take the time to do it right - letting the Cells sit for a month etc, - thats another Winter project - gives me something to do -

[shirley_hkg]

Lorry inner tube . Free.

[Burgerman]

Ebay for nylon, plastic, ptfe, tufnol, Perspex etc 1mm sheet or 2mm if you want.
http://www.ebay.co.uk/sch/i.html?_from= ... t&_sacat=0

There are thousands. Great for abrasion and electrical insulation. For the top.
Do the same for rubber sheet for the bottom.

[expresso]

ok thanks - i put it in my wish list on amazon so i dont forget it for later -

if the pack fits in my current tray which i think it will with the 15ah setup - i wont need a sheet on the bottom right ? actually my chair has a sheet like that already on top acting like a divider with the wiring of the chair etc, over it - and battery under it -

i wont mind putting a 1mm sheet anyway if it fits easily - how would i make it stay in place - - velcro maybe ? or just tape it down - rather not have to drill anything etc, -

If anyone knows of another place to get these Cells - besides EV - post a link here - i my look at other options - places to get them in the future - even though i am not in a rush - have the winter to do it - i dont like how my order dosnt seem to be moving along - and i get no feedback - tracking says the same thing for the past week -

waiting to be picked up by DHL - so it didnt even get moving yet

[flagman1776]

I use a 3M double sided mounting tape if I can afford the minimal thickness. If you need to take it apart later, the tape will tear in the middle leaving the glue. on both sides to be scraped off with a razor blade scraper.
http://www.amazon.com/3M-Heavy-Mounting ... ng+tape+3m
http://www.amazon.com/HitLights-Super-A ... ng+tape+3m
http://www.amazon.com/3M-Mounting-4-inc ... ng+tape+3m

For something I'll want to take apart: Velcro
http://www.amazon.com/Adhesive-Sticky-V ... ick+velcro
http://www.amazon.com/Scotch-Reclosable ... ick+velcro

[expresso]

Thanks - i have the double sided tape -

i think Velcro is best just on four corners in case i do need to take it off or apart - i may not even need it - but the 1mm clear plastic may be ok so i can see thru it also - i like that

Where does everyone purchase there Cells from - ?

[Burgerman]

One of my two done. This has about 1/3rd the cells.

[expresso]

Update - i ordered the remaining buss bars - i got the 2 hole also and the 4 hole type to be sure one way or another i can get this done - i got a few extra blocks also -

if all goes well now - i should have the BMS maybe end of the next week - along with the other half of my order from EV - - i should have everything by end of the month - to get this ADD on done already - at least started

[Burgerman]

Mines built all bar a couple of connecting bars... I never get enough. No idea where they all go.

[Scollard]

Yesterday I just recharged my first 20 individual cells. I have 20 more to do on Friday and 18 the following Thursday. Then I can start figuring out my groups of 7 cells to make my battery. I'm shooting for the end of the month to have everything wired up and ready to install.

[expresso]

maybe i spoke to soon about the other site for the cells etc, - i placed my order for the missing parts i needed - my mistake -

i put 72 cells in the cart - added 145 Bus bars or 150 - a little extra - about 80 Blocks etc, with shipping - i think it told me the total cost was $2100 - yikes

i tried it again with the 58 Cells 15Ah and not much different at $1900 -

so maybe i may take EV offer for the discount if i decide after all - and cross my fingers - - i cant enter there site - page is down - blank -

this is a little more than i was bargining for with the expenses - - i have to Call this a hobby now - because when its a hobby - you dont look at the costs as they add up - i already lost track - feel like i got sucked in a Black Hole - cant retreat

i am still very nervous about the whole pack thing - but will check the chair again to at least know if i do decide - what can be done - -

[Scollard]

You only need 48 cells to do the 6x8 90Ah pack, 56 if you want to add the horizontal addition.

Since you're very nervous about the fit, you should probably stick to the 6x8 pack made with 15Ah cells. I would still make a connector for adding the add-on pack, because it's so easy, and that will give you 114Ah max if your going a long way.

[expresso]

now thats a good plan - i was thinking that myself - to be safe so i dont waste all the Cells - i can always fall back and just make the 90ah pack -

and not be a total waste - i am going to double check the chair - take it apart again better to see what how i feel then -- i can check again and decide which way feels best for me -

if i get the 72 cells and then i find it hard because of space or what ever - i cant fall back to something else and dont want to get stuck with the Cells and no pack in my chair

if i do the 15ah cells - then i start with intention of doing 56 Cells - - if that fits good and i feel good about it - thats great - worst case if thats giving me problems -
then i can do the 90ah pack instead -

back up plan if one way dosnt work - i can do other way which should work for sure -

now lets say the ADD on to this pack - does the ADD On have to use a BMS - how would that work - to charge it balance that ADD on - to connect the ADD on pack to this pack - would that work the same way - just two wires SB50 connector ? no extra wires to charge or balance ?


for instance - the ADD on i hope to get done now - will use a BMS - and just plugged in my cable i have already there -

but the whole chair pack is not - so the ADD on for the whole chair - how would that ADD on get balanced -

[expresso]

http://cpecpower.en.made-in-china.com/p ... ttery.html

something like this would have been perfect for me and i am sure alot of users - - but i am sure you guys - BM will find many things with this and why its not good - which may very well be true -

just would been nice if it was a workable unit - nice size - just hang in the rear and plug it in - and its a decent amount also - 50ah extra - not bad -

[Burgerman]

You would need 2 of them but it would work if you could fit that. But its too long.

[expresso]

Whow amazing - i think this is the first time you BM agreed with me - haha - i finally found something that would work according to your standards - that means alot -

good to know - i think its 15 inches long - thats not too bad - it says 24 V - why would you need two ? - now would those need to be balanced charged also -

or can be just plugged in and charged with dumb charger

[Scollard]

Whow amazing - i think this is the first time you BM agreed with me - haha - i finally found something that would work according to your standards - that means alot -

good to know - i think its 15 inches long - thats not too bad - it says 24 V - why would you need two ? - now would those need to be balanced charged also -

or can be just plugged in and charged with dumb charger

You need 2 to get 100Ah. But are they not too low C BM? The Headway cells are 10C discharge and 5C charge but these are only 2C discharge and 1C charge.

[expresso]

i was thinking of this as the ADD ON - - -

not that i am looking to change my plans - i plan to still continue once i get all the parts in - i ordered those 4 hole bus bars - that order will be here next wed. -

if i am lucky i may have the rest - but i dont see it yet moving on the UPS site - by end of month - i should have it all ready to go - thats more than enough time -

[shirley_hkg]

i was thinking of this as the ADD ON - - -

-

You are loosing quality then.

[expresso]

Not sure why i would be - if that pack is 50ah - 24V already - - but either way - i am going to do what i planned - with your BMS and 16 Cells for now for the ADD ON -

i just found that as i search around - and was just curious about it - i dont plan on buying that - but looks like a nice pack -

[Burgerman]

bECAUSE Its low C rate and huge size.