Power in Flux
Likes Likes:  5
Page 1 of 2 12 LastLast
Results 1 to 10 of 12

Thread: Requesting help with Buss

              
   
   
  1. #1
    Senior Member Stevo's Avatar
    Join Date
    Nov 2014
    Location
    Behind the Redwood Curtain- REDWOOD ORIGINAL!!
    Posts
    549
    Post Thanks / Like

    Requesting help with Buss

    The only way I can fit this volume of batteries into what little space I have available is to separate them into 3 groups of 8 in series for a total of 24 in series. There is no other way to fit them... I've thought of and tried every possible way I could imagine with Styrofoam mock-ups.


    My question has to do with the buss between the 3 groups... Do you more experienced builders think I can safely use 2-0 cable to buss the 3 bundles? I will need to make two of them. I plan on keeping the cables as short as possible, and of equal lengths. It's the only way I can think of to connect the 3 compartments.
    Current rides: '96 Honda Ohlins VFR, '03 Cannondale C440R, '03 Cannondale Cannibal, '06 Yamaha 450 Wolverine 4x4
    Current builds: http://elmoto.net/showthread.php?t=4354

  2. #2
    Senior Member
    Join Date
    Aug 2013
    Location
    Ephraim, UT
    Posts
    234
    Post Thanks / Like
    I don't see why that should be a problem. I have a cable between two stacks of Leaf modules in my bike, and that hasn't been a problem. I just used the same wire as I did for the rest of the high-power wiring. It'll be carrying the same current unless you're doing multiple parallel banks.

  3. Likes Stevo liked this post
  4. #3
    Senior Member Stevo's Avatar
    Join Date
    Nov 2014
    Location
    Behind the Redwood Curtain- REDWOOD ORIGINAL!!
    Posts
    549
    Post Thanks / Like
    I was thinking that also. I wonder if I could get away with using 4-0 cable. Maybe overkill with 2-0 is a good thing. I think I will tape a temp sensor on to these bus cables to monitor how hot they get.

    Sent from my Pixel 2 using Tapatalk
    Current rides: '96 Honda Ohlins VFR, '03 Cannondale C440R, '03 Cannondale Cannibal, '06 Yamaha 450 Wolverine 4x4
    Current builds: http://elmoto.net/showthread.php?t=4354

  5. #4
    Empulse R #24 frodus's Avatar
    Join Date
    Aug 2010
    Location
    Portland, OR
    Posts
    2,538
    Post Thanks / Like

    My Social Networking

    Follow frodus On Twitter
    What cells are you using and how are you putting them in series/parallel?

  6. #5
    Junior Member
    Join Date
    Jul 2018
    Posts
    3
    Post Thanks / Like
    How many amps are you pushing through it continuously? And what's your longest cable run? I'm running 50mm2 (1/0) cable for 550 amps peak (30 seconds) and about 200amps continuous. The cable gauge doesn't need to be crazy, as long as your not pushing it constantly and your cable runs are within reason (1-2 meters), also what's your voltage drop tolerance?

  7. #6
    Senior Member Stevo's Avatar
    Join Date
    Nov 2014
    Location
    Behind the Redwood Curtain- REDWOOD ORIGINAL!!
    Posts
    549
    Post Thanks / Like
    Travis,
    I was able to work out a deal with Patrick (aka theFREElaker on this forum) for these never used cells:

    24 in series, no parallel cells.

    Upperfoot, the longest cables will be to the controller from the battery pack at less than 14"... probably around 10", and as far as sag and max amps, I'm clueless, maybe Travis can provide some input answering those questions. I don't know what this set up (Sevcon gen4 size6 and ME1616) will draw. The length of bus cable between the 3 groups will be approximately 6". I have 2-0 and 4-0 cable readily available.
    Current rides: '96 Honda Ohlins VFR, '03 Cannondale C440R, '03 Cannondale Cannibal, '06 Yamaha 450 Wolverine 4x4
    Current builds: http://elmoto.net/showthread.php?t=4354

  8. #7
    Junior Member
    Join Date
    Jul 2018
    Posts
    3
    Post Thanks / Like
    Funnily enough I have the same Motor / Controller setup as you. I'll be maxing my Sevcon at 660 amps with 24 of these https://hobbyking.com/en_us/turnigy-...ck-w-xt90.html (6 parallel x 4 series) for 48Ah at 100v. I use this for the voltage drop so with your criteria using 2/0 it will be https://www.calculator.net/voltage-d...=660&x=88&y=18

  9. Likes Stevo liked this post
  10. #8
    Empulse R #24 frodus's Avatar
    Join Date
    Aug 2010
    Location
    Portland, OR
    Posts
    2,538
    Post Thanks / Like

    My Social Networking

    Follow frodus On Twitter
    Kokams are awesome cells!

    I'd just make some clamps for the series connections, fold the tabs over and clamp. Might do some searching on the interwebs for kokam packs at DIYElectriccar.com.

  11. Likes Stevo liked this post
  12. #9
    Junior Member
    Join Date
    Jul 2018
    Posts
    3
    Post Thanks / Like
    This is an interesting read about Kokam pouches http://www.metricmind.com/audi/14-battery.htm

  13. Likes Stevo liked this post
  14. #10
    Senior Member Stevo's Avatar
    Join Date
    Nov 2014
    Location
    Behind the Redwood Curtain- REDWOOD ORIGINAL!!
    Posts
    549
    Post Thanks / Like
    Quote Originally Posted by frodus View Post
    Kokams are awesome cells!

    I'd just make some clamps for the series connections, fold the tabs over and clamp. Might do some searching on the interwebs for kokam packs at DIYElectriccar.com.
    I made enough room at the top to keep the tabs unfolded, then I can put a thin sheet of silicone rubber in between each series clamp to isolate them. Since the box is Al, it should absorb the heat fairly well except that it will be lined with silicone foam rubber sheet. The 6 outside cells will probably be the coolest, maybe. I'm not sure how hot the batteries will get all insulated in foam rubber for shock protection. It is a dirtbike after all, that they're going in. The lids will be fab'ed with some of the acrylic box Patrick included. It's a shame to cut the boxes up. I know he put a lot of hours work into them. But they will make nice tops. I'm planning on incorporating the Cycle Analyst's shunt and the LEV-200 into the Battery box. And the cables from the Sevcon will bolt onto the battery box lids, so that I wont have to ever unbolt the cables off the Sevcon. It will be difficult to get a wrench to.
    Current rides: '96 Honda Ohlins VFR, '03 Cannondale C440R, '03 Cannondale Cannibal, '06 Yamaha 450 Wolverine 4x4
    Current builds: http://elmoto.net/showthread.php?t=4354

Page 1 of 2 12 LastLast

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •