[DaPhish]

Hello I am very new electric conversion and ready to work on one. I have bought pretty much all the parts and in the process designing location of everything.
Below is the battery layout. There are 12 batteries total and use as 6S2P and is split to 8 back and 4 front.
The back battery will run all the way to the front and will that cause voltage difference since it is 10 ft?
Do you think this is a good idea?
I do wish to max out at 1000amp
Thanks you,
Ryan

 

[DaPhish]

Sorry I didn't specify. It 60 cells together without BMS of 10s6P. They're from battery hookup. I am using 12 of these

 

[DaPhish]

To me it's already assembled and I don't have the parts to link them together into 10s12P so I personally think this is the best way for me. If you have any other ideas I'm more than happy to consider it.

 

[DaPhish]

I have consider that but it seems like copper busbar prices are too high that's why I followed this diagram by Orion bms and It seems like it will work for me. If it does not seem like a good idea to follow orion bms I'll find a way for longer busbars.

 

[DaPhish]

I doubt you'll get 1000 amps out of that setup.

500A peak, 300A continuous on a good day, imo.

Enough to maybe run a 60kW motor for 20 minutes...

Due to the battery not being strong enough or because of my choice in wiring it?

 

[DaPhish]

I have consider that but it seems like copper busbar prices are too high that's why I followed this diagram by Orion bms and It seems like it will work for me. If it does not seem like a good idea to follow orion bms I'll find a way for longer busbars. View attachment 127748

 

[DaPhish]

As you get the modules from Battery Hookup them, each module is wired the way the Orion diagram suggests - that's good. What you are proposing to do is connect each module in parallel with another module, which is not suggested by the diagram.

So I decided to do what you proposed and this is the new diagram. Does this resolve the issues?

 

[DaPhish]

And welding cable in huge conductor diameters is relatively cheap

I don't think I could use welding able to link between the cells in my case

 

[DaPhish]

Yes, that avoids any balance issues between modules and cuts the BMS complexity in half.

The "side view" bit doesn't apply any more.

Perfect I will do that, thank you

 

[DaPhish]

How thick are the busbars on the cells now? 1/16"? Copper Sheet 1/16 Thick 52”X13” 13lbs Drop Piece It Does Have Scratches | eBay copper 1/16" x 52" x13" should be enough only $140 plus shipping it has gone up since last year when I bought a piece. You can nickel plate it fairly simply.or BatteryHook up has 6p busbars for sale now 6p 300a BUSBAR FOR SPIM08HP 16ah - Copper/Steel
Later floyd

That is a great option, thank you

 

[DaPhish]

That's 6P, and that's what he already has. To configure his battery as desired, without parallel modules, he needs 12P.

Interesting things about that busbar:

• I didn't see it when I looked, but I didn't check all of the categories
• checking all BatteryHookup products, there are only 4P and 6P intermediate plates and 6P end plates (mis-labeled as 3P)... no end plates for 4P, no plates for larger numbers of cells in parallel
• the construction is bizarre: as seen in any of the photos of these modules there is a notch in the plate exposing a copper section where the BMS tap is attached; this description suggests and the photos confirm that it is a copper plate with a steel plate over top, with the steel acting essentially as a big common washer
• the steel-on-copper construction is only for the intermediate connections, while the end cells are terminated with copper plates that extend to the module terminals (no steel)

Note that the current rating for this 6P busbar is 300 amps, which is more than needed for any rational discharge rate for these cells, but a 12P configuration would twice the conductor capacity for the same per-cell discharge rate. Much thicker copper seems like a good idea to me.

I contacted them to see if they have any 1000amp rating ones since they mentioned it. I also asked if they could produce 12P ones as well since it seems like they produce it themselves. But just I'm case they don't, is it a good idea to perhaps add one more layer and act like a bridge to create 12P?
PS I'm only hoping to pulse at 1000amp as like a quick acceleration boost and not continuous. Continuous should only be 400 max.

 

[DaPhish]

So, if with proper cooling (air) and a 1000amp capable busbar. Is it worth/capable to possibly get up to 500amp comfortably?

The cells are rated to discharge 200a continuous and able to pulse 400a. So with 12 in parallel each cell shouldn't have too much load on them right?