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Summary of Contents for Sun Fun Kits V4
- Page 1 Sun Fun Kits V4 Assembly Manual Revision 1.0...
- Page 2 Before you Begin: Thank you for purchasing your Sun Fun Kits V4 DIY heated battery kit, diy battery kits make assembling your battery quick and easy and only require basic tools and hardware to assemble. We recommend having a basic understanding of DC wiring in order to assemble your battery pack and you will also need the following tools: ●...
- 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 Fun Kits certified cells (LF280K, REPT 280, and LF304) you should be able to use 3 x 1.0 mm shims to complete the install and have a nice tight fit, however for maximum pack longevity and vibration isolating 3x 1.5mm shims will work the best. Page: 4 V4 Manual - Revision 1.0...
- Page 5 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 V4 Manual - Revision 1.0...
- Page 6 *Image shown is from the V3.5 Kit, but the install process is the same on V4. Test fit the cells to get an idea of the installation; you will now need to prepare the cells with shims. For this you have 2 options:...
- Page 7 Note: You will want to have the textured side of the shim facing the cell you installed, with the smooth side facing outward. This will ensure the shim stays in place while you install cells. *Image shown is from the V3.5 Kit, but the install process is the same on V4. Page: 7...
- Page 8 PLEASE MAKE SURE TO PLACE CELLS CORRECTLY IN THE ORIENTATION ABOVE. V4 kits support various cells and depending on your cell height you may or may not need cell spacers. For the LF280K, REPT 280 and LF304 cells sold by Sun Fun Kits, you will use the 1.5mm spacer on top of the case molded in ledges to raise the height of the support so that it...
- Page 9 Once your cells are in the correct position; it is now time to install your cell plate. With our v4 kits we have made our cell bracket universal and it should fit virtually all cells in the 270-320 AH class.
- Page 10 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: 10 V4 Manual - Revision 1.0...
- Page 11 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: 11 V4 Manual - Revision 1.0...
- Page 12 Page: 12 V4 Manual - Revision 1.0...
- Page 13 After inserting the cells you will have 2 heating pads and 1 shim, now you can place the cells spacers (shown above as the green pieces that sit on top of the molded ledges) and proceed with mounting the v4 main plate (note the cell spacers are needed for cells that are 204mm or Page: 13...
- Page 14 Route the heated cell-separator wires through the dedicated slots on the v4 kit. You will then need to crimp the heating pad wires together. The V4 kit with in-between-cell heating option includes 2 terminal lugs for this: an 8mm diameter yellow lug and a 6mm diameter black lug.
- Page 15 Bms, all wiring and prep has been done for you; simply bolt onto your components; no crimping or cutting is necessary. The V4 kit system will be focusing exclusively with the SFK-200V2 BMS initially, with support for the SFK-150V2 and other BMS units being added in the future.
- Page 16 Many of these changes are in response to queries and suggestions form our customers, we would like to thank you for your input Page: 16 V4 Manual - Revision 1.0...
- Page 17 Begin by placing your bus bars in the orientation shown below and then place a m6 washer on top of the bus bars, this is needed to provide an even and stable base for your BMS terminals. Page: 17 V4 Manual - Revision 1.0...
- Page 18 1st white wire (green lug) = cell 1 positive / (3.3 Volts) 2nd white wire (yellow lug)= cell 2 positive / (6.6 Volts) 3rd white wire (blue lug) = cell 3 positive /(9.9 Volts) Page: 18 V4 Manual - Revision 1.0...
- Page 19 4-6 NM. WARNING! Loose terminals will cause the cells & batteries to fail. You will align the balancing wires towards the main lugs leaving the center area clear for the active balancer. Page: 19 V4 Manual - Revision 1.0...
- Page 20 TERMINAL OF THE FIRST CELL OR IT WILL ARC AND DESTROY THE CELL. You should consider covering this terminal with kapton tape or other insulating material to ensure that it can not short circuit the first cell. Page: 20 V4 Manual - Revision 1.0...
- Page 21 BMS and other related electronics. Being by mounting the riser plate by first inserting the active balancer connector into the balancing unit and then rotate it so that it matches the mounting holes on the main kit plate: Page: 21 V4 Manual - Revision 1.0...
- Page 22 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: 22 V4 Manual - Revision 1.0...
- Page 23 For sidewall heating installs, you will need to secure the heating pad flap to the riser using kapton tape. This is required to ensure that the heating pads do not interfere with the tongue and groove construction of the case and lid. Page: 23 V4 Manual - Revision 1.0...
- Page 24 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 units, we provide the BMS to you with appropriately sized crimped and ready-to-install wires that you easily attach to your kit.
- Page 25 *Similar to the blue wire, the black bms to case wire is also installed inverted, this allows for greater flexibility in wire routing. Secure with the included M6 hex bolt. Page: 25 V4 Manual - Revision 1.0...
- Page 26 Heated kits shall attach the positive terminal of the thermal switch/silicone heater terminal to the final post on the lid. NOTE: be sure that the heater terminal sits ABOVE THE MAIN LUG, it Page: 26 V4 Manual - Revision 1.0...
- Page 27 Once the lid wires are secured, you can now insert the balancing wires into your BMS. Finish off by bolting down the top lid using the 4x16mm countersunk screws. USE HAND TOOLS! No Impact Drivers for this step! Page: 27 V4 Manual - Revision 1.0...
- Page 28 (low order) sealant between the lid and the lip of the battery. A good example is this brand: Simply apply a bead of it before closing the lid, we have a video of this process (shown on a v1 kit): Page: 28 V4 Manual - Revision 1.0...
- Page 29 Once through simply insert the nylon barrel into the built in latch using a flat head screwdriver: Page: 29 V4 Manual - Revision 1.0...
- Page 30 Once done your kit is now complete and ready for testing. 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: 30 V4 Manual - Revision 1.0...
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