Power in Flux
Likes Likes:  6
Page 1 of 2 12 LastLast
Results 1 to 10 of 17

Thread: Issues with a 72V Headway BMS

              
   
   
  1. #1
    Ghost Rider Allen_okc's Avatar
    Join Date
    Mar 2011
    Location
    Oklahoma City, Oklahoma
    Posts
    1,812
    Post Thanks / Like

    Issues with a 72V Headway BMS

    im sure some of us are familiar with this drawing - anyway i want to add it to my 72vdc pack so i can use just one charger which will eventually be onboard...

    i hooked up C1 thru C23 first, but when i tried to hook up the neg and pos of the balance wires they sparked severely, so i backed off, is it supposed to do that?

    the major ground from the charger and the ground to battery pack isnt hooked up yet, since i dont have any instructions on how to hook it up other than the this old pic...

    HELP!!!
    Attached Images Attached Images
    The Greatest thing about a EV, is the Song of the Terrain...

  2. #2
    Ghost Rider Allen_okc's Avatar
    Join Date
    Mar 2011
    Location
    Oklahoma City, Oklahoma
    Posts
    1,812
    Post Thanks / Like
    here is a drawing i did to show how i hooked up the balance wires - its either the pos and neg that sparks severely when i try to hook the two up...
    Attached Images Attached Images
    The Greatest thing about a EV, is the Song of the Terrain...

  3. #3
    Ghost Rider Allen_okc's Avatar
    Join Date
    Mar 2011
    Location
    Oklahoma City, Oklahoma
    Posts
    1,812
    Post Thanks / Like
    here is some pics of the pack 24S2P...
    Attached Images Attached Images
    The Greatest thing about a EV, is the Song of the Terrain...

  4. Likes Podbuilder liked this post
  5. #4
    Senior Member SplinterOz's Avatar
    Join Date
    Aug 2010
    Location
    Canberra, Australia
    Posts
    758
    Post Thanks / Like

    My Social Networking


    Visit SplinterOz's Youtube Channel
    To confirm your wiring here is a picture of mine before I pulled it all apart...


    The drawing seems to match the way it was installed on my pack with the high current +ve leads bypassing the BMS totally.
    I would recommend the you hook up the battery -ve to the BMS before attaching the balance leads.

    In the original setup all my balance leads (even pack -ve and -ve) are plugged in at the same time.
    SplinterOz
    From Australia'a Capital
    http://rgelectric.wordpress.com/

  6. Likes Allen_okc liked this post
  7. #5
    Ghost Rider Allen_okc's Avatar
    Join Date
    Mar 2011
    Location
    Oklahoma City, Oklahoma
    Posts
    1,812
    Post Thanks / Like
    Thank You, Splinter - im going to go over my balance wires again to make sure they are connected in the right places, but this time i will leave the balance wire plugin to the bms unplugged. then when all wires are connected "properly" i will plug the balance wires plugin back into the bms and then hopefully everything will be ok so i may continue to bench test the 72 volt 6 amp charger...

    hopefully everything will go right this time

    scary stuff to me, but it needs to be done...
    The Greatest thing about a EV, is the Song of the Terrain...

  8. #6
    Ghost Rider Allen_okc's Avatar
    Join Date
    Mar 2011
    Location
    Oklahoma City, Oklahoma
    Posts
    1,812
    Post Thanks / Like
    i seen a video of a 48V headway bms assembled - he assembled the balance wires to the pack with it unplugged to the BMS...

    http://www.youtube.com/watch?v=9b6yPIqrQjw
    The Greatest thing about a EV, is the Song of the Terrain...

  9. #7
    Ghost Rider Allen_okc's Avatar
    Join Date
    Mar 2011
    Location
    Oklahoma City, Oklahoma
    Posts
    1,812
    Post Thanks / Like
    i was given specific intructions on the procedure for hooking up a 72V Headway BMS;

    The first step in wiring the BMS is to connect B- to the battery’s main negative terminal.

    Next, plug in the wiring harness to the BMS board.

    It is crucial that all the wires of the wiring harness are connected in the correct order to prevent any damage to the BMS so be very careful with these next steps!

    Begin with wire # 0 (labeled on the bottom of the BMS) of the wiring harness.

    Connect the # 0 wire to the negative terminal of the first cell in series (the battery’s main negative terminal).

    Connect the # 1 wire to the positive terminal of the same cell; the first cell in series.

    Connect the # 2 wire to the positive terminal of the second cell in series.

    Connect the # 3 wire to the positive terminal of the third cell in series.

    Continue connecting the wires of the wiring harness in order to the positive terminals of each cell.

    The last wire will connect to the positive terminal of the last cell.

    One of the leads from P- connects to the negative output of your charger.

    One of the leads from P- connects to the negative terminal of your controller.

    The battery’s main positive output connects to the positive terminal of your charger.

    ================================================== ===========================================

    what i did was start on the positive side of the pack which put the wiring hookup i drew is all wrong...

    Also with the battery charger now hidden and on board of the chopper, i will present a video on how to hook up a bms with on board charger...
    Attached Images Attached Images
    The Greatest thing about a EV, is the Song of the Terrain...

  10. Likes Skeezmour liked this post
  11. #8
    Senior Member Podbuilder's Avatar
    Join Date
    Sep 2013
    Posts
    160
    Post Thanks / Like
    I ordered my headway 72v 20Ah pack and charger the other day. This info will come in handy.

  12. #9
    Ghost Rider Allen_okc's Avatar
    Join Date
    Mar 2011
    Location
    Oklahoma City, Oklahoma
    Posts
    1,812
    Post Thanks / Like
    here is a video i made for installing the Headway BMS and on board charger...

    http://www.youtube.com/watch?v=yEzQ5...ature=youtu.be


    The Greatest thing about a EV, is the Song of the Terrain...

  13. Likes Podbuilder liked this post
  14. #10
    Senior Member Podbuilder's Avatar
    Join Date
    Sep 2013
    Posts
    160
    Post Thanks / Like
    Very nice. Is that a torque screw driver you're using?

    Brad.

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
  •