My no BMS layout - Please help

ESK8 Electronics
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#1

Hi guys. I have been loitering an planning for a while now and hopefully the board should arrive today for my build (the Pork Chop Express) anyway. I have been inspired by @whitepony to leave a BMS out of my build (partly for cost but also because I’m looking for a simple rugged build to use for commuting so the less things that could go wrong the better!

Please could someone take a look at my layout below and just advise that I haven’t made any huge mistakes? I am planning on using 40 Samsung 25R batterys in to this 10s4p layout. I will still use balance cables/plug so that the cells can be periodically checked when I take the shell off.

Electrics Layout.jpg2023×1633 235 KB

I wanted to make a pack that is a little more compact than laying them flat. I have thought about doubling up the cells as below. Would this also work? (dashed line on the top diagram is where the “fold” would be.

10S4P Battery layout Side View.jpg1030×398 108 KB

Finally I have some questions about the gauge of the balance and main power cables? What should I use for each? Plan is to stay with single drive. I am planning on doubling up the Nickel (0.25mm) on the series connector. Would this be sufficient or would wire reinforcement be better?

Thanks for any advice you can give!

Norcs

#2

what is round button-like symbol between B6 and B10 ?

#3

Charger plug in possibly

#4

Sorry - I should have labeled that - yes charger port probably a 5.5mm socket.

#5

ok so you will use Antispark plug as ON/OFF switch correct?

#6

Yes that is the plan - I want to print a loop to hold/support the loop of wire as it comes out and goes back in - then I will use a spare XT90 half attached to my keys to make sure I don’t lose it.

#7

I should also ask what I should look out for when buying a charger. I know that the Evolve one used by Whitepony cuts off at 41v is this usual? Will any 36v charger have a 41 or 42v cutoff?

Something like this for example? http://www.ebay.co.uk/itm/Li-ion-Battery-Charger-36V-2-0A-2AH-Scooter-42v-Max-li-on-LIB-/182134399475

#8

Mine is wired the same way , i have the second half of the Anti spark attached to the enclosure by a strong nylon string . So i just plug in and out for my ON/OFF.

Screenshot_2016-11-28-12-25-21-960x540.png960×540 405 KB
…in pucture it is not inserted all the way

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#10

I like that. Really tidy with the mesh from enclosure to motor.

#11

Most 36V chargers will stop at 42V, I got a charger from “MODIARY” like whitepony’s , I emailed them and asked if they could change end charge to 41V and they did without charge !

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#12

I wouldn’t have even thought to do that. I think I’ll drop my charger order with the EU group buy and try the same.

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#13

the only difference in my wiring is the Voltmeter, mine is a very small one from “DROK” it has 3 wires,… 2 for powering it, which are tapped onto the wires powering the “Reciever”… and 1 wire reads the Battery Pack V on the POS side

#14

maybe add some protection between cells so they dont have abrasion between them and short and add protective donuts to the positive terminal

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#15

Yes I was planning on positive terminal rings and hot gluing the packs together. My deck should be very low flex so hopefully this will be enough to stop rubbing.

I am hoping to ABS heat form an enclosure which I will do once I I have properly planned the battery / vesc etc layout. Having seen how low @Randyc1 rides with one layer I may have to follow suit. (otherwise Ill be top mounthing on a drop thru)

#16

I actually think I might have one of those from my drone building. Was a voltmeter rather than a battery % but maybe that would be a way to go. That is 3 wires so would be wired same will have to check it is a 5v to power it.

#17

yes the Drok voltmeter can be powered from 5-30V i think,… then the other wire is good to read up to 100V

I rather V reading rather than %, this way you know excactly the Voltage

#18

Perfect. Looks like I might be on to a winner with this layout then. Just found your build - great work!

#19

Thank you.

#20

What guage wire did you use for the main leads and balance leads? I am thinking 10awg? for main leads?

#21

Yes main leads 10g

Balance 20g

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