Difference between pages "Tools needed" and "Parallel Batteries"

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(Created page with "Converting an e-bike is a simple task that only requires a few basic tools. Here is a quick list of what you should expect to need to convert a bike to e-bike. ==Metric Allen keys== Many bike parts are held together by SHCS (Socket head cap screws) that require Allen keys to undo. Metric Allen keys are used on bikes, but you might encounter some e-bike kit that uses imperial somewhere. ==Metric Wrenches== While there are not many bolts on bikes these days, e-bike kit...")
 
(Created page with "There are two methods you can use to safely parallel batteries. ==Direct connection== To safely parallel batteries directly for more capacity, you must first ensure they are the same chemistry (lipo, li-ion, lifepo4, lead acid, etc) and the same voltage. Never attempt to directly connect batteries in parallel of different chemistries. It is also best if they have a 2 wire BMS (Charge and discharge through the same wires), since otherwise directly cross connecting th...")
 
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Converting an e-bike is a simple task that only requires a few basic tools. Here is a quick list of what you should expect to need to convert a bike to e-bike.  
There are two methods you can use to safely parallel batteries.


==Metric Allen keys==
==Direct connection==
Many bike parts are held together by SHCS (Socket head cap screws) that require Allen keys to undo. Metric Allen keys are used on bikes, but you might encounter some e-bike kit that uses imperial somewhere.


==Metric Wrenches==
To safely parallel batteries directly for more capacity, you must first ensure they are the same chemistry (lipo, li-ion, lifepo4, lead acid, etc) and the same voltage.  
While there are not many bolts on bikes these days, e-bike kits may require you tighten bolts. A crescent wrench can do in a pinch but is much more likely to strip bolts. Make sure to fully tighten a crescent wrench on the bolt before applying force. Bikes are generally metric bolts.


==Crank puller and Bottom bracket removal tool==
Never attempt to directly connect batteries in parallel of different chemistries.
if installing a mid drive, generally the crank and bottom bracket must be removed and replaced. Many crank pullers and bottom bracket removal tools also require a large wrench to use. Not needed for hub motors.  


==Soldering iron==
It is also best if they have a 2 wire BMS (Charge and discharge through the same wires), since otherwise directly cross connecting them may defeat the overcharge protection.
Good for connecting wires. potentially also a soldering gun style for any extra thick wires that need to be soldered. You may be able to do without one by using certain crimp connectors and joins but its good to have.


==Digital Multi meter==
By directly connecting the positive wires to each other and the negative wires of a 2 wire BMS, you can charge both batteries and discharge them through the same wires at the same time.  
Required to diagnose any potential issues with the bike/battery.


==Crimping tools==
You must first however charge both batteries to the exact same voltage (fully charged is recommended as its easiest to reach) as directly connecting batteries of different charge states can cause huge currents to flow. Its best to verify with a DMM that they are the same voltage before connecting.
Its best to get proper crimping tools as an improper crimp could leave you stranded on the side of the road or worse, cause damage to the wiring/bike when it overheats. I highly recommend a JST crimping tool for e-bikes as many of the connectors used on e-bikes are JST. If you wish to go with Anderson Powerpole connectors, an Anderson crimper would be highly recommended as well. If you use XT60 connectors you can solder them and don't need a crimper for them.


==Wire cutter==
It is recommended to have an individual fuse or breaker for each battery, but not strictly required as the BMS should be able to disconnect the battery in event of over-current.  
Often you will need to cut wires to length or apply different connectors. Scissors can do in a pinch but you are likely to damage them. Pliers with wire cutter sections are much better or wire strippers that include a cutter.


==Wire stripper==
This means you can not directly connect a second battery in parallel as a backup unless its going to stay attached or only be attached when both batteries are fully charged. Use an A or B battery switch instead if you need to switch to a backup battery.  
Often you will have to strip wires after cutting them to length or when replacing a connector. Wire strippers will help strip the wire properly without damaging it. don't use a knife or wire cutter for a stripper. Many strippers also include wire cutting functionality and may double as one.


==Heat shrink or Electrical tape==
==Diode connection==
You will need to insulate wires after soldering them together. it is also good to use heat shrink or electrical tape to strain relieve wires that go to connectors.


==Zip ties==
By using high power diodes, you can ensure your one battery won't discharge into the other and can even connect different chemistries of battery or even different voltages, although they won't share the load if you do mix voltage/chemistries and you will need separate chargers.
Zip ties are great to secure wiring to the frame of your bike. Electrical tape could also be used but zip ties tend to be cleaner looking. Velcro straps can also be used.
 
The diodes need to be rated for higher then your max battery voltage and the full current you expect to draw, ideally much higher. This will make them rather large and likely require heat sinks. The diodes only need to be on the positive wires, directly connect the negatives. 
 
You also need to use additional diode or separate connectors for charging. If you use diodes they will need to be rated for the full current of your charger and batteries.
 
Note that if you use diodes, your controller will no longer be able to recharge your battery and regen braking must be disabled.

Latest revision as of 08:26, 15 January 2022

There are two methods you can use to safely parallel batteries.

Direct connection

To safely parallel batteries directly for more capacity, you must first ensure they are the same chemistry (lipo, li-ion, lifepo4, lead acid, etc) and the same voltage.

Never attempt to directly connect batteries in parallel of different chemistries.

It is also best if they have a 2 wire BMS (Charge and discharge through the same wires), since otherwise directly cross connecting them may defeat the overcharge protection.

By directly connecting the positive wires to each other and the negative wires of a 2 wire BMS, you can charge both batteries and discharge them through the same wires at the same time.

You must first however charge both batteries to the exact same voltage (fully charged is recommended as its easiest to reach) as directly connecting batteries of different charge states can cause huge currents to flow. Its best to verify with a DMM that they are the same voltage before connecting.

It is recommended to have an individual fuse or breaker for each battery, but not strictly required as the BMS should be able to disconnect the battery in event of over-current.

This means you can not directly connect a second battery in parallel as a backup unless its going to stay attached or only be attached when both batteries are fully charged. Use an A or B battery switch instead if you need to switch to a backup battery.

Diode connection

By using high power diodes, you can ensure your one battery won't discharge into the other and can even connect different chemistries of battery or even different voltages, although they won't share the load if you do mix voltage/chemistries and you will need separate chargers.

The diodes need to be rated for higher then your max battery voltage and the full current you expect to draw, ideally much higher. This will make them rather large and likely require heat sinks. The diodes only need to be on the positive wires, directly connect the negatives.

You also need to use additional diode or separate connectors for charging. If you use diodes they will need to be rated for the full current of your charger and batteries.

Note that if you use diodes, your controller will no longer be able to recharge your battery and regen braking must be disabled.