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Old 02-27-2016, 05:12 PM   #57
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Here is the block diagram of what I am implementing for my trailer. I hope to have options listed with the material list.

More details to follow:
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Old 02-27-2016, 06:44 PM   #58
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Quote:
Originally Posted by BigAl View Post
Hey Mike,
Is that down to 70% or down 70% with 30% remaining?
Al
Down 70% with 30% remaining. I believe the cells have to drop below 3.0v's before they start dipping into the 12's. I have yet to attempt to really deplete the system.

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Originally Posted by sgschwend View Post
You likely have four series cells. I put this one together with three ....
Yup, 4 sets of 3.2V cells wired in series, then in parallel. So a total of 16 cells. Basically I have 4 12V battery's if you want to look at it like that for ease of understanding. I just find the differences interesting. I am planning on buying some of the 18650 cells that are used in Tesla batteries to build a backup for my laptop.
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Old 02-28-2016, 08:19 AM   #59
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Subscribed - very interesting project!
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Old 03-01-2016, 07:07 PM   #60
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Material List:
Item/Price/Source
Battery, Chevy Volt 12 cell, $550 Ebay plus shipping
Battery cover, $30
BMS 100A, $60, Electric Car Parts Company
Charger 10A, 12.6VDC max, $139, plus shipping
Bussmann 100A Circuit Breaker, $28, Amazon
Bayite 100A power meter w shunt, $20


Notes:
  1. A blank source line means same as above
  2. The Bayite display is praised and hated. Easy to install, and seller replaces for free. It would have been nice to find a better device that wasn't ten times the cost.
  3. I recommend you only purchase the battery and cover for the EBAY seller. However, he will provide a complete battery with BMS for a price. His solution is below my standards in materials and circuitry wiring. My thinking is for the money the buyer should obtain all the capability this system has to offer and not end up with low cost materials and a partially wire system.
  4. Remainder of the material is miscellaneous material, such as wire, connectors. I am trying to improve on the battery lug wiring, looking for a crimp connector or a drill fixture.
  5. Total for the BMS and charger with shipping $224
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Old 03-05-2016, 09:22 AM   #61
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Update: the battery has been running the trailer for two week, some furnace time, lights while we remodel the bathroom and kitchen.

Here is the final battery strapping.
Improvements:
  1. Bolt together non soldering method of assembly,
  2. No crossing of the power leads,
  3. All leads are home runs,
  4. Provides a smaller gauge wire for the BMS to use for balancing,
  5. Able to separate the cells for possible troubleshooting,
  6. Simple drill fixture that make drilling the bus bars error free.
The overlay lines are the new connection, painted on top of the old wiring method.

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Old 03-08-2016, 07:45 PM   #62
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Here is the new battery wiring method. I believe the results are better and easier to obtain. Final results:




Here is the tool I used to drill a hole without the drill slipping or shorting the battery.


The tool is a 2", 1/4" diameter role pin, welded to a vice grip pliers. The pliers have been grounded down to provide the maximum clearance. Clamp and drill.

Then make jumpers with bare 12 gauge crimped eyes (crimp and solder). Use hex head 6/32X1/2" screws and self locking nuts; the hex head is necessary to allow the use of two open end wrenches for tightening, you can use tape to isolate the wrenches. The power jumpers are 12 gauge, the balancers are 16 gauge (yellow and blue).
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Old 03-11-2016, 10:00 AM   #63
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Fanastic work and thread.
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Old 03-11-2016, 12:35 PM   #64
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I've always tried to follow and discern what may have caused those Li battery fires that get reported, whether it is a cellphone/laptop fire that burns down a house, fires on the initial 787 flights or the new hover boards. It seems that they are caused by an internal manufacturing defect in the battery that only surfaces during periods of high current draw or charging.

While you're probably more likely to get struck by lightning then have a Li battery fire, being a nervous Nellie, I'm wondering, would the BMS protect against this?
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Old 03-11-2016, 03:49 PM   #65
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We covered that in another thread, the ones you hear about are a completely different chemistry.
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Old 03-11-2016, 08:26 PM   #66
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Yes the BMS protects the battery and the load, also the power distribution system.

I have attached a set of specs for a BMS to give you a feel for what they can do. The BMS is smart enough to allow a high starting current for devices such as a tongue jack, but with a dead short it quickly disconnects the battery.

Have you ever taken a look at what happens to an automobile's wiring harness when there is a short in one wire? It melts several if not all the wire in the harness, this too can cause a fire. If the automobile had a BMS this would not happen.

In the years 2006 to 2010 there were 17 car fires an hour, 2/3 of theses were mechanical or electrical system failure (lead acid battery). Source National Fire Protection Association.

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Old 03-19-2016, 07:20 PM   #67
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Battery Project is Finished, Here is a video tour:


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Old 03-19-2016, 10:05 PM   #68
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Thanks for sharing! Very interesting indeed.
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Old 03-21-2016, 08:44 PM   #69
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Here are two documents I produced. The first one explains the BMS and charging, the second is the updated material list.

As an update: The battery is installed in the trailer, when the charger was connected it reported SOC and then charged the battery up to 12.4 VDC. I have reassembled the fuse box and only need to re-install the interior skin I removed to run the power meter cable up to the upper cap end radio opening, where the power meter is installed.

If anyone has any question post them or PM me. Steve

BMS explained.pdf

Material list.pdf
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Old 09-11-2016, 11:13 PM   #70
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So I've read through this thread four or five times. Steve, is the battery functioning as designed? Maybe you mentioned this before but did you forgo individually balancing each cell?

In case any one is as dense or not electrically inclined as I am, here's a link with someone using this battery for a electric bike, he breaks down the basic components of the battery pack.

LINK!
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