S646se - Full LITHIUM Pack Project - First Attempt

[expresso]

thats good to know - those are easy to find around if that ever needed - i doubt that very much now

it would take a day or two to get full anyway with only 8A charger -

[Burgerman]

105Ah divide by 8A = 13 hours...

The hard part is knowing when the first cell gets full and goes high...

If it ever happens use a your spare PL8 and connect it to any car/taxi/bus/whatever and charge for 30 / 40 mins at full power. That will put about 7 to 10 miles back...

[expresso]

i am not going to carry a charger any more - thats the reason i did this - to be free of chargers which dont do anything anyway - 8A would take 13 hours -

if that ever ever did happen - a short charge to make it home maybe - but with all the miles i have now - i be tired in bed before that happens

[Scollard]

You could always carry your add-on and if you run low you then know you have a extra boost to get you home or onto a bus.

Very good job Expresso.

[Burgerman]

You could always carry your add-on and if you run low you then know you have a extra boost to get you home or onto a bus.

Be best to connect at the start. Not sure how many amps will flow if you connect a full lithium to a discharged one. It could be a *lot* compared to what happens with a soft/high resistance lead battery. Maybe more than the addon cable will like.

I do this when connecting hobby lipos to charge in parallel. Sometimes they get very warm. And parallel balance boards include poly fuses that reset themselves.

[expresso]

You could always carry your add-on and if you run low you then know you have a extra boost to get you home or onto a bus.

Very good job Expresso.

thanks - yeah i am not really worried now - and i would connect the ADD ON from the start if anything - no use hanging on the chair and not connecting it - i cant imgaine how it feels if i ride for 30 or 40 miles - 22 miles was a trip

discharging today and recharging tonight - and thats it - will wrap it up - get my chair in order - attach the cables to the chair - and wait for someone to lift it and put it in there -

[expresso]

ok done - i will get my chair ready later - hopefully get it inside the chair tomorrow

[expresso]

the amp section i can lower it just a bit more - its at 250ma now - when it finished it was fuller - a bit lower - by the time i snapped the pictures - it changed a bit

i can put it to 200ma and see how it works next time

[expresso]

i posted the wrong results -

these are the latest charge

[Burgerman]

Dont lower it. Its perfect as it is.

I notice that its set to 35A charge, but only charging at 30A... You still have something set wrong in the supply tab.
I charge at 40A regularly so I know it will!

[expresso]

yes i noticed that also about the charging - i though it just pulled what it needed - i will post a snap of the supply tab - you can tell me what i am missing there -

to my surprise - i got it installed last night - my two girls did the job - its a very tight fit on the sides - no room for wiring much - i had a plan to route the charge cable and ADD on cable differently but turned out i wasnt able to snake it under the frame into the battery box as i though i could - so i ran them outside and in the side of the battery box - - i used velcro and tape to keep them in place - they are not moving from there - after all was done - to close up the battery case - there are two knobs that get screwed in - one on each side - well the side where i added the charge cable - i wasnt able to put it back there - it was in the way - and i wasnt going to untape it to fix it - so i left it with just one side locked in -
which is very strong - the rear case wont open - i can either cut the screw a tiny bit - to try - but run the risk of damaging it - and then cant install anyway - so i left it alone -

the wiring was hard to connect with the pack in place - such a tight fit - and since the wiring was routed differently from what i expected - it took more wire - so not alot of slack - its done - so hopefully wont have to touch it again -

now its time to start riding it to see and program it to adjust - once i get my laptop upgraded now - i decided to get the free Win 10 - will take a few days to complete i had so many updates to install - i forget it set it not update at first because i didnt want Win 10 - i changed it back to down load and let me decide what and when to update it -

here are the last of the pics - thanks to my girls here - one of them Quickiee2 - shes the one with the GB motor issues - well she got the chairs back and same thing - battery issues with that one chair - still dont hold a charge - and the other they changed the joystick - and guess what - it dosnt work !!! taking it back to change it again - same thing joystick - amazing - they didnt even test it -

anyway - i hope she either changes repair vendor - and or starts process for new chair but get the same one as mines - then i can make her a 105ah pack

[expresso]

done

[expresso]

turns out the little space i had on top where the top Row dosnt cover - was useful to keep the wires on that side there - since theres no space on either side of the pack for wiring - which i didnt realize

its a perfect fit - i didnt do anything to the divider - the divider gets lower in the front of the chair as compared to the rear that you see in the picture - in the front it dosnt have the same amount of space - its screwed in the front to PM cover which pulls it down in the front - thats why the Lead batteries were so tight when in there in the front the rubber on the posts were stuck under the divider there -

this pack is just like Scollard said - a touch over 9 inches high - its under 9 and 1/2 inches - for sure - i would have liked more room for wiring to be neater in there - i hope its ok when pushed in place - how ever they ending up -

i will see when recharging it if all is working - i checked with the volt meter and its all good after the install - both cables - good thing i did use the xt90 connectors - for the size - Anderson would be harder to stick in there -

only the main chair got the anderson which snapped in fine - SB50 - will go for a short spin today - - i wont charge it again till i used about 20 miles - or so just to see -

[Burgerman]

22 miles on your other chair with addon, used about 55Ah. So in this full pack chair you should have about 50Ah to spare!
In other words you should have 40 miles range even without the addon. This one though is a different chair, so may use more (or less) Ah per mile.

Track it for say 5 miles or so then recharge to find out. (And knock 0.5Ah off for every 10 returned to see what was used).

With lithium every Ah is usable. If you ever get to the last orange light, stop. Because thats almost completely empty. And countable. And because zero peukert, theres no range penalty for traveling full speed.

[terry2]

@expresso
Well done dude. Looking really nice. What controller are you going to use with the full pack?

[Burgerman]

His controller on that chair is r-net 120.

B sure there are drain holes in that plastic tray/sheet.

[expresso]

@expresso
Well done dude. Looking really nice. What controller are you going to use with the full pack?

thanks - working great - did my first 10 miles today - not going to charge - will wait for 30 miles before charging again - over the weekend -

[expresso]

His controller on that chair is r-net 120.

B sure there are drain holes in that plastic tray/sheet.

Ok now what do you mean drain holes ? i tapped it around the battery tray like a wall - so nothing would get in - dirt - rocks etc, who knows what -

its not totally sealed on top -

i cant leave it this way ?

[Burgerman]

If water or condensation starts to fill it up, it may finis up as a bag with an inch of water in the bottom. Stick a screwdriver through it in a few places to be sure.

[expresso]

ok what i will do is - open the cover and just cut a opening in the back area - a big square opening - that should be more than enough to air anything out -

will do that now since i have quickiee2 here with me now -

[expresso]

hows this - i cut a big opening -

[expresso]

the tray itself dosnt have any holes in it -

is this good enough now ? to breath some

i didnt think it needed anything since all the ready made packs i see or fully covered sealed complete -

[Burgerman]

Yes but in rain, its the bottom that collects water. How long would it take to air out 2 inches of water from a bucket?

[expresso]

ok but why would rain get in there first place - i never had rain in my tray before -

thats why i covered it so nothing will get in there to start first i dont ride in the rain - if i happen to get stuck out and it rains - thats different -

i can always pull it out to check if i ever get stuck in rain when i got home -

just to know - would it have been OK to just stick it in there with nothing around it ? just fully exposed ?

[terry2]

His controller on that chair is r-net 120.

B sure there are drain holes in that plastic tray/sheet.

So I could use this pack with my DX2 REM550 controller and get the extra miles?

[Burgerman]

You could use any 8S lithium ion phosphate battery on any mobility device.

[Burgerman]

just to know - would it have been OK to just stick it in there with nothing around it ? just fully exposed ?

Yes as long as nothing can short out the bus bars. You only need stab the bottom with a screwdriver so no standing water.

[expresso]

just to know - would it have been OK to just stick it in there with nothing around it ? just fully exposed ?

Yes as long as nothing can short out the bus bars. You only need stab the bottom with a screwdriver so no standing water.

you mean the bottom of the actual Tray itself - i understand - but that plane took off long ago that had to be done if anything at the very start when i had the tray outside exposed with nothing in it -

i think i be fine - in 15 years of wheelchair use - i never had water inside my battery box - unless this thing gets submerged in a pool - its not going to happen - i cut that part of the plastic in the rear of the pack just to let it breath i guess -

the rest is wrapped around the the tray and tapped - nothing is getting in there - the divider is on top - - now i have a opening because i cut it open not to suffocate it i guess - i am more concerned at the wire really on the O and 8 - since it comes outside the pack and around - i will keep a watch on it over time to make sure its not getting bent or pressure on it - with the case closed - its not touching it really - but from riding or up hills etc, - i would think it may lean on the rear cover or downhills - the same for the front -

i have to check it every summer time - - worse case - in the winter - take it out and replace those wires - longer and routed inside and over - - little things i noticed i could have done better - even the charging cables - but no way of really knowing till you do it and stick it in there to see - unless it gets test fitted back and forth to see what can be done before - which was never done - never test fitted - built once and stuck in there

i think its fine and should be for a long time - but in the event - i take it out and redo those two wires

[expresso]

BM - i can do that once i get my laptop running again it suppose to me same speed but does seem faster than the other chair - and it is heavier i think -

will do tomorrow night - i dont use my outdoor chairs indoor unless i have to -

[Burgerman]

Do you now see the value of say the little cell log that shirley sent you yet?
Or the Ah counter and voltage/Amps/watt hour/meter that I use from Turnigy? It shows Ah used up, as you drive. They are limited to 65Ah so need a restart at this point. But still helpful to see what you are using while indoors, on hills, on the flat etc.