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-   -   Club Car DS Lithium Conversion - 150ah 14s goodness (http://www.buggiesgonewild.com/lithium-club-car/152469-club-car-ds-lithium-conversion-150ah-14s-goodness.html)

gree7363 05-02-2019 09:57 AM

Club Car DS Lithium Conversion - 150ah 14s goodness
 
All,

Wanted to post up my 14s 48v lithium battery conversion and see what everyone thought. Its a 150ah 14s pack, or ~8kW battery, with about 5-6kW of usable energy.

https://i.imgur.com/QviRRGNh.jpg

Prepping the old wiring (meaning ripping out the crap the previous owner had hacked / sliced together)

https://i.imgur.com/UgZpxDmh.png

First view of how I plan to wire up the BMS. I went with a Chargery BMS 16t which will handle the balancing and charge/discharge mains. It can balance at 1.2a which is great considering this is a 150ah pack. Also has a nice screen to show SOC and turn on/off the pack.

https://i.imgur.com/0XBjwb5h.jpg


Yay, batteries! Did some size up of how the box would look.

https://i.imgur.com/Z6ywnqPh.png

Some disection of the pack and my plan for cooling / heating. The packs have resistive heaters on the outside by design so that will be used when I take this ice fishing to keep the pack happy.

https://i.imgur.com/sJr0FCIh.jpg
https://i.imgur.com/MSXtNeXh.jpg
https://i.imgur.com/ydSiDYjh.jpg

gree7363 05-02-2019 09:58 AM

Re: Club Car DS Lithium Conversion - 150ah 14s goodness
 
Original hope was to be able to drop these in the original slots but they were wayyyy to big.

https://i.imgur.com/umrlvWHh.jpg

This whole setup will be enclosed in an aluminum box that is sealed. This is to keep water / dust / dirt out, and as far as venting I have 2 temp probes monitoring the 2 packs at all times. If temp gets too high, i'll eventually have forced air cooling, which will dissipate through the walls of the case. should be enough.

https://i.imgur.com/79Bhdcph.jpg

Part of this project for me was also to learn how to Tig weld. I'd not done it before so picked up an Everlast tig welder and started practicing. The welds aren't perfect, but **** am I proud of my box.

https://i.imgur.com/YWjLmmfh.jpg
https://i.imgur.com/1jAbwm2h.jpg

Next step was to make a spot for the battery to sit securely. Did this by welding up some angle and welding it to the frame of the cart. Surprisingly strong. Had to knotch out some of the frame to make it fit and clear the seat, but the welded angle should provide enough re-support for it, honestly the frames are pretty beefy anyway.

https://i.imgur.com/rcAWR21h.jpg
https://i.imgur.com/1jldwylh.jpg
https://i.imgur.com/5V2a2onh.jpg

Back to the battery. Hooked one up to check BMS and see how cells looked. Needed some calibration but working well!

https://i.imgur.com/usezHJth.jpg

Connected batteries in parallel and checked current flow between them, as they were not the same voltage. Pushed about 20a from one pack to the other for a while and allowed them to equalize before connecting the balance leads. Didnt want that current to flow between cells, rather than from pack to pack and burn out the small balance wires.

https://i.imgur.com/xyBWy3qh.jpg

Now to the fun part, battery assembly and layout. Everything is 2awg in the box. A Charge circuit relay capable of 60a continuous, and a discharge relay capable of 200a continuous. The discharge will be upgraded soon as I have an alltrax 500a coming in the mail :)

https://i.imgur.com/ThaxYqgh.jpg
https://i.imgur.com/IKPEA7ch.jpg

Had to mount the 600a shunt in there, without touching metal... designed and 3d printed this mount.

https://i.imgur.com/XpTzTlih.jpg

Everything mounted and batteries secured with steel squish straps to maintain pressure on the cells. (orange straps to help me and wife move it into the cart)

https://i.imgur.com/fqy8LVjh.jpg

And the final product. There she is in all her glory.

https://i.imgur.com/WxVzKrnh.jpg

Finally added a small box to fit the BMS Display on the dash of my cart.

https://i.imgur.com/sixrqemh.jpg

All in all, i love it. Its overkill, but who wouldnt want an 8kw, 700a capable, 14s4p, 48v (58.8v fully charged), 150ah battery pack that is basically bullet proof for future mods?


-Dave

NCPW 05-02-2019 10:35 AM

Re: Club Car DS Lithium Conversion - 150ah 14s goodness
 
Nice work! :thumbup:

Where were your cells sourced from and how do you like the Chargery BMS and charger so far?

gree7363 05-02-2019 11:33 AM

Re: Club Car DS Lithium Conversion - 150ah 14s goodness
 
Quote:

Originally Posted by NCPW (Post 1610780)
Nice work! :thumbup:

Where were your cells sourced from and how do you like the Chargery BMS and charger so far?

Cells are from Greentechhybridbatteries on Ebay. They are from a Kia Soul EV.

Bms is OK, it is helpful to see the cell voltages and the alarms and relay control are nice, but i wish it had more customization on how the relays were able to be controlled and whatnot. I can do everything i want with it, but a little more would be nice.
As for features and its balance current capabilities, its amazing! I see SO many batteries with dinky little 50mA balance current ratings and they just cannot bleed enough power fast enough if your charging at, say, 20a and a cell is high to keep it safe. I'll take my 1200mA any day over 50mA, but again alot of people dont think about it. With this setup, i see no more than 25mV under load difference in my cells, and the active monitoring is great. It even stores the cell voltages if an alarm were to go off so you can look back and see what everything was at when it happened. Particularly nice for charging over-night to ensure nothing happened while you were sleeping.

I have the pack set to 4.2v/cell though these cells are rated up to 4.3v due to their chemistry, and my min voltage cutoff in my controller is set to 3.0v. So im well within their full charge potential.

Each module is 14s2p, max voltage for these packs, however is 60.2v, not the typical 58.8 like most 14s packs.

For charging I have a 20a, 60v PSU running a buck converter thats capable of 15a. The buck is CC/CV and I set it to my charge voltage (58.8v) and limit current to 10a to keep heat down. Charger is enclosed in a metal box with server fans to keep everything cool. Done this in the past with a custom go-kart battery and the charger works great.

NCPW 05-02-2019 11:59 AM

Re: Club Car DS Lithium Conversion - 150ah 14s goodness
 
Good to hear! :thumbup:

I think you're the first person to actually document using the Chargery BMS so that's why I asked. We've had a few use them for their lithium conversions, but never really report back with their experiences or results. Also, you're the first on here that I know of to use Soul modules for a build.

I've really enjoyed my ZEVA BMS so far but it's always good to have options.

Let us know what kind of range you're getting when you get time to drive 60 miles straight :mrgreen:

gree7363 05-02-2019 12:04 PM

Re: Club Car DS Lithium Conversion - 150ah 14s goodness
 
Quote:

Originally Posted by NCPW (Post 1610824)
Good to hear! :thumbup:

I think you're the first person to actually document using the Chargery BMS so that's why I asked. We've had a few use them for their lithium conversions, but never really report back with their experiences or results. Also, you're the first on here that I know of to use Soul modules for a build.

I've really enjoyed by ZEVA BMS so far but it's always good to have options.

Let us know what kind of range you're getting when you get time to drive 60 miles straight :mrgreen:

It actually saved my A** with one of my packs, because i was getting really big voltage swings on the cells.

The pack in question actually had some shipping damage, i suspect UPS dropped the package the damaged module was in.. I ended up tearing the whole pack apart to check everything out and 2 of the series battery tabs welds had come off, so i had to re-spot weld them on and everything worked exactly as it should after that.

Cant really fault the supplier, there was clear box damage on the 1 of 2 modules I purchased (shipped together but 2 packages) but i didnt catch the internal damage until the BMS showed me all kinds of problems, though the pack was driving the cart no problem. Without that feedback it would have certainly ended in disaster.

All in all, i'd recommend for sure.

BBBHC 05-02-2019 04:08 PM

Re: Club Car DS Lithium Conversion - 150ah 14s goodness
 
Thanks for sharing your build. Looks well done!

So are you using relays for HV/LV shutoff?

gree7363 05-02-2019 04:18 PM

Re: Club Car DS Lithium Conversion - 150ah 14s goodness
 
Quote:

Originally Posted by BBBHC (Post 1610893)
Thanks for sharing your build. Looks well done!

So are you using relays for HV/LV shutoff?

yep one relay for each. Bms has a histeresis value i can set in time (sec) in how long above or below the set value until the bms shuts the contactor off for the corresponding H or L relay.

gree7363 05-06-2019 01:49 PM

Re: Club Car DS Lithium Conversion - 150ah 14s goodness
 
Just added a 500a Alltrax XCT and holy crap this thing is crazy.

NCPW 05-06-2019 08:10 PM

Re: Club Car DS Lithium Conversion - 150ah 14s goodness
 
:thumbup:

Wait 'til you add a torque motor :burnout:


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