While I’m trying to figure out how to fix my blown VESCs, I might as well kill some time and do a quick post on how I built my balanced LiPo battery for my E-MTB.
Materials: 1x Pelican 1200 case 3x 5000mah Hard Cased Lipo Battery 1x 48v 2.5ah scooter charger from Ebay 1x 40a 12S BMS from Ebay 1x Velcro with adhesive side
I started off with the LiPo batteries. I’m not going to bother taking them apart because I’m lazy. Instead I’m going to directly connect their balance wires to the BMS.
The Ebay BMS actually came with its own 12 pin balance cable, so the first thing to do is to liberate that 12 pin connector.
I do the same to the LiPo batteries, and begin transplanting the freed balance wires into the 12 pin connector. Balance leads are live, so it’s best to do one at a time.
Did this for all the batteries. Eventually ended up with this. Also note how I excluded all the black balance leads.
Now time to connect the batteries. I cut off all the plugs and tried to make the connecting wires as short as possible.
The final result ended up looking like this.
Now to wire up the BMS power leads. Firstly I didn’t take pictures of this part (my bad), but there are plenty of guides on exactly how to do this, so take a quick look around. However the important part that I have to stress is that my BMS has a 40a fuse. You CANNOT connect your ESC to the power out on the BMS, unless you want to blow that fuse. Instead, I wired the power out plug directly to the LiPo battery(s).
Here’s the final result after I fitted everything into the Pelican 1200 case.
Final Notes: The bullet connectors that I cut off the batteries were later reused as charging connectors for the scooter charger and the BMS. The power out of the battery is an XT90 connector Holes were drilled in the back (close to the bottom) of the Pelican 1200 case Everything you see in the final product is either Velcro’d or Friction fitted Charging is as simple as plugging this thing into a wall socket I sneeze in order to detect the polite people in the room