The "NON-BMS" BMS Conversion photos (part 1)

[Juiced]

The "NON-BMS" BMS Conversion

I am splitting up the main sections of the conversion/load testing/assembly/road test as the posts tend to get too big for some people to want to read it ALL.
No reason they cannot read it all, but for those who want to see the high points, here they are.

The Disclaimer: (Again) This is just a different way of running a BMS for our particular application.
There are many good (and expensive) BMS's, but they all had limitations to our particular bike. (cost, size, POS, etc)

Here is the battery Pack with the Headway installed BMS.

As you can see, not the best setup for a vibrating motorcycle.

We will be fixing That!!!

In the box is the older version BMS. Good for charging, but not enough capacity for the LVC.
I have received new and improved 72 volt - 24 cell units that do work well. I will be selling all of the new extra units soon.





96 Cells, all load tested (see other Post) charged with the single cell units and ALL sitting at 3.33 volts ready for assembly.





Here is the first batch of TOP plates.

**** NOTE!!!****

These cells are all slightly different size in length. Solid top plates are fine if you use the single cell to cell jumper taps (see first photo) to keep undo stress off of the cells.



As soon as I have the molex connectors in I will take a few more photos.

More later!!!!

[frodus]

nice work! keep the pics comin!

[larryrose11]

Ed: Looking good!
with this set up, you just eliminated all but 1 BMS, if you keep the original setup.
Make sure that contact areas are all clean. You don't want any cell heating up because of some contact resistance.
Some heavy load testing in order perhaps?
I know that a thin coat hanger across a deep cycle sla will pull about 90A in the air @ about 12.0V so, that's 12.0/90A = 0.13 Ohms.
Caution, the paint stinks when it burns off!
You could test a half pack of 36V, that would pull 36/0.13=270A!!

[Juiced]

Thanks

All of them are clean and tested. (Please see other posts!!! )




HEY Ted! Notice the fuse!!!!!! (top photo)


Ed

[gasfreeearth]

Originally Posted by frodus

nice work! keep the pics comin!

Ditto. Ditto.

[larryrose11]

Ed,
I was talking about how to exercise (part) of a pack and feel for warm / hot spots so you can further tighten them down.

[Juiced]

Hey Larry.

I sort of gathered that.

I have several posts about the testing of the batteries and I thought that was what you were refering to.

I have typed way to much today.

Thanks for the info!!!!


POooped Ed