View Full Version : The "NON-BMS" BMS Conversion

08 September 2010, 1727
The "NON-BMS" BMS Conversion

The Disclaimer: 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.

96 Cells, all load tested and 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.

More later!!!!

08 September 2010, 1747
what kind of batteries are those with bolt tops?

08 September 2010, 1754
Headway 8AH high power.

See Travis (frodus) about getting some. They work GREAT!!!!!


11 September 2010, 0347
Ed, do you have a link for those chargers?

11 September 2010, 0737
Here are the new chargers that I swapped to.

Lifepo4 Chargers (https://p10.secure.hostingprod.com/@www.voltphreaks.com/ssl/catalog/product_info.php?cPath=3&products_id=28)


26 October 2010, 0107
Headway 8AH high power. Do these batteries also have bolts for the negative? How does this pack look from the underside?

26 October 2010, 0625
Yes they do and the same as the top.

The system has been working great. Been riding alot lately since the weather is nice.

26 October 2010, 0648
oooo! ooooo! Can I show him my breaking Headways video, can I huh can I? :D

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25 November 2010, 1500
Upgraded to "86" volts today. Added a separate Radio shack box in series with 8 more headways. (2S4P)

Full charged and right off the charger it is at 93 volts. After an hour it goes to 87/88 volts. When riding it sits at 86V for most of ride (at rest).

Now running 26S4P. Have batteries for 26S5P, but need a bigger frame.
No data on range yet as I want to beak in the "new" batteries.
I will not get any more speed as I have the controller set up for distance
and limit the volts to the motor. It will still do 65/70 MPH if needed....got to love it.

More later.


27 November 2010, 1109
2.75kWh should go 30 plus miles in your setup! Do I smell another build from the "master builder"?

27 November 2010, 1831
Hey Bruce!

I have gone 36 miles so far. I am looking for a bigger frame as I have extra batteries that are sitting around.
I have been keeping them charged, but not being used in...something is a waste.


28 November 2010, 1906
Hey Bruce!

I have gone 36 miles so far. I am looking for a bigger frame as I have extra batteries that are sitting around.
I have been keeping them charged, but not being used in...something is a waste.


How about a side car? Carry extra batteries that connect in parralel whith the main pack and carry the significant other when you just want to bomb around town together.
Don't know how you feel about side cars, just a thought....

28 November 2010, 2012
That would be interesting, but no where to put the bike and sidecar in the garage. Plus you have to get a spacial license in SC for one. I thought about saddle bags.The wiring would be a nightmare.

I am still looking. I may modify the present frame.

Where is Terry when you need him?


04 December 2010, 2211
Hey Ed, I bought one of these chargers to play with, but I have a question. It says they're fully isolated so that you can use multiple chargers, but what exactly is isolated from what, and how is it isolated?

05 December 2010, 0449
The best way I can explain it is that it means isolated from a opposite polarity doing damage to it from another charger.
How it isolates is due to it sensing too much voltage in the opposite direction (or a short) and shutting down.
If you short the wires together, it just stops working until you let them go.

I have 8 chargers going to 8 sets of batteries using only 9 wires.

The positive from the first charger is joined to the negative on the next charger.

Works great.