S646se - Full LITHIUM Pack Project - First Attempt

[expresso]

Lead... eBay!

thanks - i wish you told me lead earlier - i got steel plate shipped already from ebay - 3/8 inch - will see how that fits i guess -

[expresso]

http://www.pureleadproducts.com/lead-sheet/

That might be a place to try, but lots of places offer custom sizes etc. Google "Lead sheets" or "Lead plates" you find tons of options!

1/4" thick = 16lbs per sq ft. 3/8" = 25lbs per

thanks - i found that place also - will make a few calls - just to see if they can make a custom size - etc, and at what cost -

i believe my steel plate will be about 18 lbs not too bad - was cut to size and cost cheap - ebay - i will have to move the divider up higher i am sure - to make it fit - i will call the tech - get him over here on his free time to help me with that and install my tires - hes willing to do it on his off time -

[expresso]

Fill the void of the battery cover , with a mixture of lead shoot and glue .

It will be heavy , and far back .

i have no clue how you would do that - i dont have a battery cover - its a battery tray - the pack just sits in it - i have it wrapped around so nothing can get in there - plastic sheet -

you mean pour loose lead and glue it inside the battery tray where the pack is in ? that dosnt sound very safe to me - and how would i remove the pack if that was the case after its glued down ? i am sure i am missing something here -

[shirley_hkg]

The flip down back door .

[expresso]

The flip down back door .

Ok never though about that area - but i cant - i added packing on both sides of the pack - to cushion it and make it a nice tight fit when i close the back and lock it down - its touching its snug - dosnt move -

i felt it did move before - thats how the end wires were getting bent - and after the crash - fixed it nice and packed it so it cant move once its closed - but good idea though - i will check it when i add this plate just to see - if in fact there is some room -

i am not going to turn this into a huge project - the plate i got - if it fits - is a plus - 18 to 20lbs added on the bottom - 105ah pack is about 65 lbs - total - approx 85lbs - compared to 110 lbs of lead it replaced - short 25lbs if i wanted to keep it the same weight -

still not bad - i just have to keep that in mind - i dont ride around tilted or seat lifted etc, - but i did lift it up all the way to take video of the areas - to be honest - i am not crazy of the feeling riding that high up - i cant compare how it felt with lead - not sure if i used it when i had lead only -

i never liked moving around when lifted up - the cracks on the floor - uneven ground - and now this is on my mind - and its something to think about - not looking to get disabled now

[Burgerman]

One of the reasons I ordered the Storm X-plore chair is that I no longer have a chair with a riser. And cant reach the top of my van or shelves to clean. I never drive about or even use it when out and about. I have no feeling of being 'left out' or hard to communicate etc. So no real need. Usually prefer compact lighter chairs. But tilt as on a couple of my chairs is nice. This new one has leccy everything. Power (Centre) footplate, recline, tilt, riser, etc. Probably overkill and heavy as hell... I just wish the arms were more substantial as if they are like most invacare chairs they will be wobbly and weak. But I can weld! And its way too nose heavy.

[expresso]

when i ordered this chair - i started it with out the seat lift - just tilt - but changed my mind after i realize it can be useful - and had to start the order again all over to add the seat lift in there - now that i have it - its GREAT - helps alot -

when i transfer off the chair - its perfect to get me up easy - and can be used to sit down also - instead of falling into the seat - i can lift it make it easier - i mostly just use it to get off the chair - tilt is a must - to adjust the position since most come where they sit too forward low in the front when all the way down - so the tilt is used to even it out and angle it back just a touch - its useful for many things once you have it - but to ride around or move around when up high - NO - dont like to use it that way -

when going out in a place to eat - thats where i would use it also - normal height tables dont work for me - so i would pick the counter height table and lift up to the perfect position where i feel comfortable - who knows in the future - one of my chairs - maybe i try a recline - power leg etc, - but not yet - i dont like all that stuff on the chair - - for now - seat lift and tilt does the job and chair still maintains a decent look to it

[F3Head]

I figure i start this new section for this project -

ok Scollard - i be ready to place the order by end of week - i want to make sure i got it correct - the parts needed -

Goal - make a full chair - lets shoot for the full 105Ah pack - 15ah 40152S Cells - but if i feel its too close for my comfort in the chair etc, - i can then leave it at the 90ah pack and leave off the extra 8 on top - No BMS this time

1. 58 15ah Cells - with the free buss bar and orange blocks -
2. 35 4 hole buss bars
3. 10 extra orange blocks ? or more ?

this is from EV -

is this all correct ?

i am still thinking how the 8 Cells on top will be connected etc, - but i leave it up to you - in due time -

thanks again - and of course BM and anyone can jump in - ideas etc, allways helpful -

Is there any chance you can provide pictures of your lithium powerpack project if it's not too much trouble? Unless I missed it somewhere in the thread. just curious…

Thanks, F3HEAD

[rustyjames]

I'm pretty sure Expresso posted pictures in this thread.

[expresso]

viewtopic.php?f=2&t=5702&start=340

page 18 - i think i start with pictures -

[snaker]

@expresso: Did you fit a fuse in the discharging cables? If so what amps rating is it? Do you remember its code name or do you keep the link of where you bought it?

[shirley_hkg]

THE same rating as your chair that came with .

[Burgerman]

Its job is to prevent fire from a burning battery cable. So as long as it fails after the chair is at full power, and before the cables melt its good! If in doubt 100A to 130A is common.

[snaker]

@BM: I prefer this kind of fuses but having higher rating 100A-130A as you recommend. I mean it's encapsulated like a tiny box. Do you know its code name or its brand?
http://www.store.revolectrix.com/Cellpr ... able?ext=F

[Burgerman]

Those are not high enough rated.

You need https://www.google.co.uk/search?q=midi+ ... 79#imgrc=_

Search little fuse / MIDI and holder. http://www.pcscables.co.uk/1643-midi-fuse-holder.html

[expresso]

@expresso: Did you fit a fuse in the discharging cables? If so what amps rating is it? Do you remember its code name or do you keep the link of where you bought it?

Do you mean the cables that are connected to the Charger PL 8 ? when you charge your chair or discharge it etc, - if so - those cables have a built in fuse 40A already -

if you mean the Chair itself - If your chair is already fused - you may not have to do anything to your battery - if the fuse is on your lead batteries - and you remove those batteries to add Your own lithium pack etc, - then you would use a fuse on your new battery that you will be using -

most chairs that i seen all have a 70A breaker - when i removed my lead batteries - and added my lithium pack - i added a breaker to it - its rated at 100A -

i got it from here

https://www.waytekwire.com/products/136 ... -Breakers/

they have many kinds - look around - lugs also are great from here

[snaker]

I mean a fuse in the discharging cables. I plan building a pack like yours. So, you are using a 100A breaker instead of a fuse. Maybe I will choose a MIDI fuse with a holder that BM points above.

[expresso]

I mean a fuse in the discharging cables. I plan building a pack like yours. So, you are using a 100A breaker instead of a fuse. Maybe I will choose a MIDI fuse with a holder that BM points above.

i am not clear what cable you are talking about - when you say discharging cable - which cable are you talking about ? the Cable on the Battery Pack you will build - ? you need to fuse your new battery one way or another -

breaker - fuse - which ever you like - if your chair wiring is already fused which goes to your battery Main cables - then you have a fuse in the system - if you dont have a fuse in the Chair wiring which goes to you battery main power connector - then you have to fuse the battery pack -

[Burgerman]

Any time a battery can be shorted, on all cables coming out, be it charge, or to connect to or to drive a chair, it must be fused.
The fuse must be on or close to the battery. It must be able to supply either charge current, or expected load from in this case a powerchair. And its job is to protect the battery wiring.

If theres any wires you can short out without a fuse, then it requires one!

[steves1977uk]

I think what snaker is referring to is the cable from the pack to the Power Module. I have a 120A midi fuse on mine.

Steve

[snaker]

Sorry about my bad English. Yes, I meant "discharging cables" are the cables connect between the pack and the power module. They are inside the battery box and only expose their anderson connectors to the outside.

[hobie1dog]

I finally read through all 45 pages of this thread, thanks to all who contributed.