Advertisement
Quick Links
Advertisement
Related Manuals for Sun Fun Kits V3.5
Summary of Contents for Sun Fun Kits V3.5
- Page 1 Sun Fun Kits V3.5 Assembly Manual Revision 1.2...
- Page 2 Before you Begin: Thank you for purchasing your Sun Fun Kits V3.5 DIY battery kit, the diy battery kits makes assembling your battery quick and easy and only requires basic tools and hardware. We recommend having a basic understanding of DC wiring in order to assemble your battery pack.
- Page 3 Preparing your battery cells: Sun Fun Kits DIY battery kits support various prismatic cells, in this manual we will be using the EVE LF304 type, however the process is the same for other manufacturers such as CATL, REPT, Ganfeng and more, the V3 Kit includes spacers and other items to ensure maximum compatibility for cells in this class (270-320 AH) Certified Automotive Grade Cells generally do not require balancing;...
- Page 4 1 set of 1.5mm and 1.0mm shims (3 pieces each). The shims should be placed between the inner cells and most installs will use about 3 shims. For Sun Fun Kits certified cells (280K and LF304) you should be able to use 3 x 1.5mm shims to complete the install and have a nice tight fit.
- Page 5 B cells or swollen cells as it provides the most amount of spacing for the cells. Begin by placing your cells in a series configuration with the left side of the battery having the positive terminal on the lower left and the negative terminal on the lower right. Page: 5 V3.5 Manual - Revision 1.2...
- Page 6 Note: You will want to have the textured side of the shim facing the cell you installed, with the smooth side facing the empty space. This will ensure the shim stays in place while you install cells. Page: 6 V3.5 Manual - Revision 1.2...
- Page 7 PLEASE MAKE SURE TO PLACE CELLS CORRECTLY IN THE ORDER ABOVE. V3.5 kits support various cells and depending on your cell height you may or may not need cell spacers. For LF280K and LF304 cells sold by Sun Fun Kits, you will use the 4mm spacer on top of the aluminum braces to raise the height of the support so that it matches the cell.
- Page 8 The heated kits will provide additional resistance to cells when they are being installed, however, there is still sufficient space to insert the cells. It is recommended that you do not install fully charged cells as they will make the process challenging. Page: 8 V3.5 Manual - Revision 1.2...
- Page 9 4 cells. The direct contact nature of this option means that the cells will heat up faster so there is a potential of having a bigger delta in temperature between the cells and the rest of the case. However, this method will provide for superior cell heating. Page: 9 V3.5 Manual - Revision 1.2...
- Page 10 Once attached you will be able to place this into your battery case (note in this case there are no heating elements on the sides of the case walls). As with the non-heated kits, place the leftmost and rightmost cell first, ensuring they have the correct polarity before installing. Page: 10 V3.5 Manual - Revision 1.2...
- Page 11 1.0m or the 1.5mm shim depending on how tight you want your install to be (the tighter the better for most installations). The textured side of the shim should be facing the cell while the smooth side should be exposed. Page: 11 V3.5 Manual - Revision 1.2...
- Page 12 (shown above as the green pieces that sit on top of the aluminum brackets) and proceed with mounting the V3.5 main plate (note the cell spacers are needed for cells that are 204mm or taller, if you have 200mm tall cells you do no need to add the cell spacers on Route the heated cell-separators through the dedicated slots on the v3.5 kit.
- Page 13 DO NOT CRIMP BOTH wires of the same pad together it will not complete the circuit. Which wires you chose does not matter as long as the wires being crimped are not from the same pad. Page: 13 V3.5 Manual - Revision 1.2...
- Page 14 Bms, all wiring and prep has been done for you; simply bolt onto your components; no crimping or cutting is necessary. The V3.5 kit system supports various BMS devices from manufacturers such as JBD (SFK Series), Daly, Ant, QUCC, and more. New device support is being added constantly; if you need a specific mounting plate made, simply contact Sun Fun Kits support at cs@sunfunkits.com...
- Page 15 Begin by aligning your buss bars as follows: Page: 15 V3.5 Manual - Revision 1.2...
- Page 16 M8 Nylon Lock nuts as they provide excellent anti-vibration capabilities without needing thread locking compound. Please note your BMS wires should be routed to the positive terminal and the active balancer wires should be routed to the negative terminal. Page: 16 V3.5 Manual - Revision 1.2...
- Page 17 You will need to ensure a tight fit, take care not to strip your battery terminals, if you are using a torque wrench you will want to tighten down to 4-6 NM. WARNING! Loose terminals will cause the cells & batteries to fail. Page: 17 V3.5 Manual - Revision 1.2...
- Page 18 Make sure the wired main lugs are the ones that touch the cell terminal and only stack the other bms and active balancer rings on top. Page: 18 V3.5 Manual - Revision 1.2...
- Page 19 All V3.5 RTB kits include the active balancer, and we highly recommend using it as it reduces the balancing stress on your BMS and is able to balance out cells significantly faster during charging. Once you have verified the wiring has been installed correctly, you can now begin by attaching the top plate &...
- Page 20 The SFK-200 V2 BMS is an excellent choice for this as it has a dedicated heating port that is activated during low temperature charging. Page: 20 V3.5 Manual - Revision 1.2...
- Page 21 For heated kits it is recommended to use kapton tape to secure the wires and flap of the silicon rubber heating elements to the sides of the riser plate. Page: 21 V3.5 Manual - Revision 1.2...
- Page 22 Install the m4x15-25 mm bolts on the bottom, and the m4x15mm bolts on the top. NOTE: Make sure the balancing lead is NOT connected to the BMS! This will be inserted in a later step. Page: 22 V3.5 Manual - Revision 1.2...
- Page 23 With the plate secured, it is now time to start attaching the terminal cables to the BMS, this will vary depending on which BMS you are using, for all Sun Fun Kits BMS, we provide the BMS to you with appropriately sized crimped and ready-to-install wires that you easily attach to your kit.
- Page 24 The default / safer option are the flanged top bolts as they make loose terminal bolts impossible while also providing a height benefit as they are about one inch shorter. Once you have determined your mounting preference, take your preferred mounting option and attach your top lid. Page: 24 V3.5 Manual - Revision 1.2...
- Page 25 NOTE: be sure that the heater terminal sits ABOVE THE MAIN LUG, it should never be below it as this will result in a poor connection resulting in a high resistance connection and will cause damage to your battery. Page: 25 V3.5 Manual - Revision 1.2...
- Page 26 Optionally, if you would like to have a moisture/water resistant seal, you can use electrical safe silicone (low order) sealant between the lid and the lip of the battery. A good example is this brand: Page: 26 V3.5 Manual - Revision 1.2...
- Page 27 The last step in your kit assembly is to attach the handles & grips. This process is very simple: thread the nylon rope through the plastic barrel and through the hole on the kit handles. Page: 27 V3.5 Manual - Revision 1.2...
- Page 28 Once through simply insert the nylon barrel into the built in latch using a flat head screwdriver: Once done your kit is now complete and ready for testing. Page: 28 V3.5 Manual - Revision 1.2...
- Page 29 Monitoring Apps & Tests: You can now connect to your battery and perform tests; visit Google Play Store or Apple IOS App store and search for: Sun Fun Kits BMS https://play.google.com/store/apps/details?id=com.companyname.sfkble&hl=en&gl=US https://apps.apple.com/tt/app/sun-fun-kits-bms/id1600445506 Page: 29 V3.5 Manual - Revision 1.2...
Need help?
Do you have a question about the V3.5 and is the answer not in the manual?
Questions and answers