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Summary of Contents for Sun Fun Kits V3
- Page 1 Sun Fun Kits V3, V3 Heated, & V3 RTB Assembly Manual Revision 1.2...
- Page 2 Before you Begin: Thank you for purchasing your Sun Fun Kits 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 Assembling your battery 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: 4 V3 Manual - Revision 1.2...
- Page 5 We recommend adding the left most and right most cells first and then adding the remaining 2 inner cells in the end. PLEASE MAKE SURE TO PLACE CELLS CORRECTLY IN THE ORDER ABOVE. Page: 5 V3 Manual - Revision 1.2...
- Page 6 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: 6 V3 Manual - Revision 1.2...
- Page 7 Once your cells are in the correct position; it is now time to install your bottom bracket. With our v3 kits we have made our cell bracket universal and it should fit virtually all cells in the 270-320 AH class. The one differentiating factor is cell height, these can vary from 200mm up to 205.25mm;...
- Page 8 Install the bottom bracket with the M5 bolts and washers, you can use power tools to assist in this step. NOTE: Ensure the negative and positive signs on the plate match your cells. Page: 8 V3 Manual - Revision 1.2...
- Page 9 The heated kits look similar to the regular v3 kits except they have a notch cut on the upper and lower middle to allow the wires from the rubber heating elements to extruded into the main case. Setting Up Electronics & Cell wiring: This step involves wiring up your cells, you will need a BMS system and optionally a supplementary balancing device to complete this step.
- Page 10 Now you will add your series terminals and BMS balancing/monitoring wires as well as the active balancer wires (NOTE the initial negative post; and the final positive post are shared between both the active balancer & BMS, all other posts may be separate for each cell) : Page: 10 V3 Manual - Revision 1.2...
- Page 11 “dig” into the metal, the material on the balancing and active balancing rings may not be sufficient to handle this, hence a washer above and below the terminal is recommended. Page: 11 V3 Manual - Revision 1.2...
- Page 12 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 6-8 NM. WARNING! Loose terminals will cause the cells & batteries to fail. Page: 12 V3 Manual - Revision 1.2...
- Page 13 All V3 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.
- Page 14 Secure the riser plate using the 3 countersunk M4 screws. We recommend only using hand tools for this process (despite the youtube videos where the installer and author of this manual uses an impact hammer… Page: 14 V3 Manual - Revision 1.2...
- Page 15 The heated kits will power the silicon rubber heating elements either form dedicated ports on the BMS, or they will use a temperature active switch that is included with the v3 heated kits. If using the thermal switch, it has been pre-programmed to provide heating to the battery to maintain 70 degrees internal case temperature.
- Page 16 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: 16 V3 Manual - Revision 1.2...
- Page 17 SFK-150V2 BMS; this is the BMS we recommend for our kits and works extremely well giving the most flexibility and reliability. Install the m4x25-30 mm bolts on the bottom, and the m4x15mm bolts on the top. Page: 17 V3 Manual - Revision 1.2...
- Page 18 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 19 BMS which may cause your cells to drain below the critical 2.5 volts level. Page: 19 V3 Manual - Revision 1.2...
- Page 20 With your cables prepped and mounted, it's now time to determine how you will want to mount your cable lugs to your battery kit. The V3 kits include 2 options: Terminal Studs as well as flanged top bolts. The terminal stud option is preferred as it offers the best flexibility in terms of parallel and series connections, however the flanged top bolts provide a height benefit as they are about one inch shorter.
- Page 21 ENSURE A TIGHT FIT! You must make sure the bolt is making proper and solid contact to the brass insert, a loose contact will generate heat and can lead to battery failure. Ensure at least 10-15 NM torque setting (appx 140 inch/lbs). Page: 21 V3 Manual - Revision 1.2...
- Page 22 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 4x15mm countersunk screws. Page: 22 V3 Manual - Revision 1.2...
- Page 23 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: 23 V3 Manual - Revision 1.2...
- Page 24 Once through simply insert the nylon barrel into the built in latch using a flat head screwdriver: Page: 24 V3 Manual - Revision 1.2...
- Page 25 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: 25 V3 Manual - Revision 1.2...
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