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Unread 11-13-2018, 08:33 AM   #121
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Default Re: Club Car DS lithium upgrade and 4-Link

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Originally Posted by Sergio View Post
There are folks here using it with 14 modules, You wire the BMS exactly the same as You do with 7 modules.

The only difference is that each BMS shunt will handle 4 cells in parallel instead of 2 cells in parallel of the 7 module setup, which means the BMS ability to shunt is reduced.

Are those aluminum bus bars? if so make sure you have something like NO-OX-ID A-Special Electrical Grade between the bar and the copper bases of the modules.
Thanks Sergio

That's interesting to know in case I ever want to double my pack. I left room in the battery tray area for that very reason if I ever wanted to expand. Now it makes it more tempting seeing as I wouldn't need to buy another BMS or EVMS.
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Unread 11-13-2018, 08:46 AM   #122
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Default Re: Club Car DS lithium upgrade and 4-Link

Here is a drawing of my pack using 14 modules c00-16 are where the tap wires connect.

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Unread 11-13-2018, 09:14 AM   #123
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Default Re: Club Car DS lithium upgrade and 4-Link

Oh, Duh! I don't know how I forgot about your build Jkerle!
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Unread 11-13-2018, 09:19 AM   #124
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Default Re: Club Car DS lithium upgrade and 4-Link

Thank you Sergio,

they are aluminum because i couldn't find local copper bus bars and i am impatient. Where do people here buy their copper? 1/8 inch ok? This was more of a proof of concept before i actually build it correctly. i plan to make copper bars and 3d print plastic housings similar to the stock leaf ones to enclose it all. I had these cells laying around from when i built an electric model T and figured i might as well use them now that my lead acid batteries in my golf cart were dead. I drove the cart this am with this pack attached and the acceleration is definitely being limited by the stock speed controller im thinking these can be reprogrammed?
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Unread 11-13-2018, 10:30 AM   #125
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Default Re: Club Car DS lithium upgrade and 4-Link

You can look on ebay or sites like grainger for stock copper bars.

I would use 1/4 x 1 stock, but keep in mind that aluminium carries almost 50% less current than copper if you go that route.
https://stormpowercomponents.com/***...U-AL-chart.pdf
The spacing between holes should be 1-1/3" (1.33333"), but hopefully folks here can verify that spacing for their 60AH modules.

You can print a template with the correct spacing and use a center punch on the soft copper to get the hole location marked, then just use a bench press to drill the holes.

Make sure the leaf module terminals are clean (use light sanding to remove any oxidation) and apply antioxidant before bolting the busbar.

I would also slide a piece of 3/4" plywood over the threaded bars on each end of the pack before tightening the nuts to make sure the modules cannot expand if heated.

There are quite a few install threads on the site so you can get ideas on box designs, materials and assembly.
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Unread 11-13-2018, 02:04 PM   #126
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Default Re: Club Car DS lithium upgrade and 4-Link

Just to help out.....here's the link to the ZEVA web site: http://www.zeva.com.au
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Unread 11-13-2018, 05:06 PM   #127
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Default Re: Club Car DS lithium upgrade and 4-Link

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Originally Posted by ysrman View Post
Thank you Sergio,

they are aluminum because i couldn't find local copper bus bars and i am impatient. Where do people here buy their copper? 1/8 inch ok? This was more of a proof of concept before i actually build it correctly. i plan to make copper bars and 3d print plastic housings similar to the stock leaf ones to enclose it all. I had these cells laying around from when i built an electric model T and figured i might as well use them now that my lead acid batteries in my golf cart were dead. I drove the cart this am with this pack attached and the acceleration is definitely being limited by the stock speed controller im thinking these can be reprogrammed?
You can't go wrong with McMaster Carr.

Here is a link to McMaster Carr copper page.
https://www.mcmaster.com/copper

Choose Copper,Brass & Bronze ans then on next page choose Multipurpose 110 Copper Bars with Rounded Edges. Reasonable prices and shipping. Very fast shipping. ships from Atlanta.

Check out the 3D layout of a terminal cover for 7 leaf modules. Had to zip the file. You'll have to save it and unzip it. If you 3D print this, you only need a 3/32" clear plastic cover. See pic.
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Unread 11-13-2018, 05:09 PM   #128
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Default Re: Club Car DS lithium upgrade and 4-Link

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Originally Posted by PingEye3 View Post
You can't go wrong with McMaster Carr.

Here is a link to McMaster Carr copper page.
https://www.mcmaster.com/copper

Choose Copper,Brass & Bronze ans then on next page choose Multipurpose 110 Copper Bars with Rounded Edges. Reasonable prices and shipping. Very fast shipping. ships from Atlanta.

Check out the 3D layout of a terminal cover for 7 leaf modules. Had to zip the file. You'll have to save it and unzip it. If you 3D print this, you only need a 3/32" clear plastic cover. See pic.
That's awesome!

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Unread 11-13-2018, 06:12 PM   #129
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Default Re: Club Car DS lithium upgrade and 4-Link

Yeah.....that's a very nice terminal cover. I heated and formed a piece of plexiglass I purchased from Home Depot and it's just "adequate". His appears much more than adequate!!

Nice work!!
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Unread 11-13-2018, 07:13 PM   #130
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Default Re: Club Car DS lithium upgrade and 4-Link

What are the dimensions? I don't have access to a printer so am trying to upload online but its asking for dimensions for the quote.

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