PINNED - Lithium battery conversion/info

[terry2]

Get it fitted. Still check cell connections on 3 4 5 but its good enough.

I will re-check the connections on 3-4-5.

I have got to take the centre foot stand off to get to the chairs cables.
I have bought a fuse hold that will be fitted.

Then a friend is going to put them in the chair as I can't move them

Thanks to all for your help.
Can't wait till testing time

[expresso]

Very good Terry - you will be very happy with the range - summer is here

[steves1977uk]

I use one of these 125A Littel fuses... https://www.littelfuse.com/products/fus ... eg125.aspx Hasn't blown since my pack was built in late 2014.

Steve

[Burgerman]

Bit big physically though. The midi fuses are way smaller.

Holder.
+
Fuse.

https://www.ebay.co.uk/itm/MIDI-STRIP-L ... zCXWSQFKKw

Get the 100 or 125A

And a couple of ring terminals for 5 or 6mm bolt.

[terry2]

I use one of these 125A Littel fuses... https://www.littelfuse.com/products/fus ... eg125.aspx Hasn't blown since my pack was built in late 2014.

Steve

Thanks dude.
I did get the one BM has posted about.

Bit big physically though. The midi fuses are way smaller.

Holder.
+
Fuse.

https://www.ebay.co.uk/itm/MIDI-STRIP-L ... zCXWSQFKKw

Get the 100 or 125A

And a couple of ring terminals for 5 or 6mm bolt.

I have got the holder coming.

May I ask a silly thing? Are these cells supposed to lose charge over night?
Maybe 2-4%

[Burgerman]

How are you determining a loss of charge?
The VOLTS will fall, to the natural 3.3xx level in time. They are still full.

[expresso]

Terry - they will fall to there normal voltage but no worries - thats how they are - i charge night before full - go to sleep and use the chair next day - no need to recharge again before you go out - you have a Ton of Range there

[Burgerman]

What is it to fit again? Speed?

[terry2]

Very good Terry - you will be very happy with the range - summer is here

Sorry I missed your post. Thanks dude.

How are you determining a loss of charge?
The VOLTS will fall, to the natural 3.3xx level in time. They are still full.

Thank you.
Now I understand.

What is it to fit again? Speed?

Puma 40. I travel 6 miles on the road @6-8 mph
My 2 MK gels need a recharge after I get to the hospital

[Burgerman]

These wont. You should get four times the range.

Dit you order a small cell alarm/fuel gauge thingy?

https://www.banggood.com/ISDT-BattGo-BG ... rehouse=CN These are OK. I got one. You can manage fine without. Take 10 days to turn up.

[terry2]

These wont. You should get four times the range.

Dit you order a small cell alarm/fuel gauge thingy?

https://www.banggood.com/ISDT-BattGo-BG ... rehouse=CN These are OK. I got one. You can manage fine without. Take 10 days to turn up.

So about 24 miles at 6 mph woooooooo

Yes I have got that monitor.

I've set the alarm to go off at 3.2V as I find my monitor about 0.100 out.

I am going to redo the connectors on 3-4-5 to try and get them all the same balance.

[Burgerman]

What are you checking it with? Mine is pretty close to a calibrated 600 quid fluke!

So about 24 miles at 6 mph woooooooo

I would expect 2x that. But dont test that yet till you are using tht meter and watching to see which cell drops down first. It will happen quite suddenly. At which point you stop or cause damage.

[terry2]

What are you checking it with? Mine is pretty close to a calibrated 600 quid fluke!

So about 24 miles at 6 mph woooooooo

I would expect 2x that. But dont test that yet till you are using tht meter and watching to see which cell drops down first. It will happen quite suddenly. At which point you stop or cause damage.

I compared it to what the PL8 software was showing.

[Scooterman]

When out and about do we check the voltage on load or off load? If off load do the cells have to rest for X mins before checking voltage?

[Burgerman]

Both.

Not below 3V off load, half a minute is long enough. That tells you state of charge.
2.5V on load. That varies WITH load. So it will drop a lot as you climb a ramp or accelerate from a standstill hard. Worse as it becomes more discharged.

[Scooterman]

Thank you BM, I've made a note of the values

[shirley_hkg]

Are you using an external XLR socket directly connected to the batteries Shirley? I'd be very surprised if you're pushing 20A through the pod's XLR port!

Steve

No gimmick . Use just one XLR. Tried 22.25A max. See page 129, 133.

Switched to PL8, and removed BMS became obsolete . We put a D-sub to it so we can charge our LiFePO4 in a protected way with dump charger in the absence of a PL8 , when we are away from home , eg travelling .
They are of over-voltage cut-off @3.65V

Page 92: https://www.wheelchairdriver.com/board/ ... start=2730

[terry2]

I'm now just waiting for a friend to bring me his wheel ramps to me.
Then I can start on wiring the chair

[Burgerman]

Yet you were terrified and thought it was all beyond you 2 weeks ago.

[terry2]

Yet you were terrified and thought it was all beyond you 2 weeks ago.

My bill for my monthly man nappies would not agree

[Burgerman]

Wiring the chair is easy. Just make 1 lead with an anderson on it with a 125A fuse and 10sqmm cables.

Did you make a charge connector using the 40A SubD connector?

[terry2]

Well the cells are in. But it's not a pretty sight
I checked it with the cell monitor and it's alive

I was on my own and it took my from about 11am till now to fit the cells and wires.
But I never knew that the battery box on the Puma only has two slots for wires.
Both are on the wrong end for me.

So for now I have just tucked the earth and positive wires in the back till I can find a better way.

I have to put foam on both sides of the cells to stop them moving.
Then Put the centre foot stand back on. And wait till my mate comes back tomorrow to put the chair on the ground.

The Puma has very little space to work in. I could just about put a mini ratchet in to tighten the nuts.
I will charge it in the morning once I have finished putting the chair back together.

And report back then.

[terry2]

Wiring the chair is easy. Just make 1 lead with an anderson on it with a 125A fuse and 10sqmm cables.

Did you make a charge connector using the 40A SubD connector?

That is really nice. But I can't fine solder anymore. So I have 2 leads.

[Scooterman]

I managed both packs insulated. I’m reasonably pleased with how they’ve turned out. Shirley’s parcel arrived this afternoon so I can carry on with the install . But I need to get help lifting the scooter seat off cos it’s v.heavy and awkward.

[terry2]

I managed both packs insulated. I’m reasonably pleased with how they’ve turned out. Shirley’s parcel arrived this afternoon so I can carry on with the install . But I need to get help lifting the scooter seat off cos it’s v.heavy and awkward.

That's looking GREAT
You must have loads of room.

Well my chair nearly back together. But I can't use it!
I missed placed the Monitor ext lead. So I have 2 more coming.
Don't think they will be here till next Monday

[Scooterman]

Thank you. Yes I'm lucky, big scooters tend to be more accessible than powerchairs.

I was a little bit annoyed as I should have arrange the cell order in the two packs as a pair (mirror image), as it would have made the connections more symmetrical looking. But I'm not breaking one apart to do that now they're made. I always make mistakes, my brain tends to go south, I get SO annoyed with myself

[shirley_hkg]

@Scooterman , I leave you an open end of the net sleeve of the main charge cable . Cut the excess , drip some hot glue , and seal it with the shrink tube attached , with a hair dryer .

DON'T TRUST ANYONE . When you have finished all battery wiring , check the JST end to ensure every voltages are in proper order , BEFORE YOU PLUG IT INTO PL8.

[Scooterman]

Will do Shirley, good advice

You made a nice job of the cables, very professional.

[Scooterman]

Can someone check these connections please?

A while back for the links I bought 6mm pvc (fine strands) and 6mm lugs.

On hindsight I probably should have bought 10mm, but the scooter only draws 100A max continuous (single motor), and I'm a lightweight.

I was gonna double up on the series links as shown in diagram. I messed up making the second pack, cells 8 should have been where 5s are and 6 & 7 respectively.

Green are the node wires, will it balance or

I will probably use some of shirley's thick silicone cable for 24v to controller. In diagram it's shown as 2 x 6mm

EDIT because the seat post is inbetween the two pack, the series links between 4 & 5 will be longer than the rest. There's nothing much I can do about that.

[shirley_hkg]

IT IS CORRECT !