ellum68
Newly Enlightened
- Joined
- May 8, 2009
- Messages
- 51
After taking six hours to charge the 26500 cells for my Mag458 with my Pila IBC, I decided there has to be a better way. The idea of a hobby charger became much more attractive, but I really wasn't to keen on the idea of having to using magnets if I wanted to balance my cells. So, I built myself a cradle.
First you'll need an enclosure wide enough to accept all your cell holders. This cradle is wired in series using a floating negative connection so you aren't limited to a certain number of cells you can charge. I wanted a seven slot charger, so I added seven negative banana jacks to the front of the enclosure, one positive to the side, and another hole on the side for my balance harness. I wired the balance harness with the red on the positive banana jack (yes, I know "duh") and the first negative wire next to the red on the harness to the negative banana jack on the far left. I consider this position one. The next black wire in the harness went to position two and so on.
The lid that contains the battery holder is wired in series. Simply take all the negatives from the holders and drop them straight down to the banana jack terminals below. The postive side is a little different. Take the positive connection from cradle number one and run it straight over to the positive banana jack terminal. Then the positive from cradle number two goes the banana jack negative terminal number one, cradle three positive goes to banana jack number two negative and so on. Your last banana jack negative will have no positive going to it.
Now the "tricky" portion of this build is getting your balance charger harness correctly wired up to your charger. I ended plugging my balance harness from the cradle into the balance adapter board included with the charger and then making custom harnesses from the board to the charger depending upon the number of cells being charged. By "custom" I mean I simply popped the wires out of the harness plug and shuffled them around in the correct order. So I have a harness for two cells, three cells, and so on. I followed the diagram on the last page of this hyperion manual here... http://www.allerc.com/Pictures/LBA10-A123-Manual-ENG.pdf . I simply used a continuity tester to figure out my final connection. I dropped one lead on the negative of cell holder number one and the probed around on the connector side of the balancer board until I found the right one and then wired my "custom" harness accordingly.
I know this probably wasn't the most eloquent description ever written, but I'm just glad my little brain managed to muster an idea that was an original to me. Granted I "borrowed" a bit of knowledge after reading LuxLuthor's magnet post.
http://www.250r.us/misc/hyp1.jpg
http://www.250r.us/misc/hyp2.jpg
http://www.250r.us/misc/hyp3.jpg
http://www.250r.us/misc/hyp4.jpg
First you'll need an enclosure wide enough to accept all your cell holders. This cradle is wired in series using a floating negative connection so you aren't limited to a certain number of cells you can charge. I wanted a seven slot charger, so I added seven negative banana jacks to the front of the enclosure, one positive to the side, and another hole on the side for my balance harness. I wired the balance harness with the red on the positive banana jack (yes, I know "duh") and the first negative wire next to the red on the harness to the negative banana jack on the far left. I consider this position one. The next black wire in the harness went to position two and so on.
The lid that contains the battery holder is wired in series. Simply take all the negatives from the holders and drop them straight down to the banana jack terminals below. The postive side is a little different. Take the positive connection from cradle number one and run it straight over to the positive banana jack terminal. Then the positive from cradle number two goes the banana jack negative terminal number one, cradle three positive goes to banana jack number two negative and so on. Your last banana jack negative will have no positive going to it.
Now the "tricky" portion of this build is getting your balance charger harness correctly wired up to your charger. I ended plugging my balance harness from the cradle into the balance adapter board included with the charger and then making custom harnesses from the board to the charger depending upon the number of cells being charged. By "custom" I mean I simply popped the wires out of the harness plug and shuffled them around in the correct order. So I have a harness for two cells, three cells, and so on. I followed the diagram on the last page of this hyperion manual here... http://www.allerc.com/Pictures/LBA10-A123-Manual-ENG.pdf . I simply used a continuity tester to figure out my final connection. I dropped one lead on the negative of cell holder number one and the probed around on the connector side of the balancer board until I found the right one and then wired my "custom" harness accordingly.
I know this probably wasn't the most eloquent description ever written, but I'm just glad my little brain managed to muster an idea that was an original to me. Granted I "borrowed" a bit of knowledge after reading LuxLuthor's magnet post.
http://www.250r.us/misc/hyp1.jpg
http://www.250r.us/misc/hyp2.jpg
http://www.250r.us/misc/hyp3.jpg
http://www.250r.us/misc/hyp4.jpg
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