TRAMPA 21700 User Manual

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21700 PCB Battery Pack - V2

USER MANUAL

Version 2.1

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Page 1 21700 PCB Battery Pack - V2 USER MANUAL Version 2.1...
Page 2 Welcome to the 21700 PCB Battery Pack Manual! Please read and understand ALL THE INFORMATION included in this manual, before assembling or operating the battery pack. Failure to follow the instructions and safety precautions outlined in this document may result in damage to the product, personal property or serious injury.
Page 3: Table Of Contents
Contents 21700 PCB Battery Pack USER MANUAL Welcome to the 21700 PCB Battery Pack Manual! Contents Warning Messages List of Components Tools for Assembly Mechanical Assembly Steps VESC Tool Connect to the VESC via Bluetooth Discharge Settings Battery Charging & Storage...
Page 4: Warning Messages
Warning Messages Throughout the manual the following terms will be used to indicate the various levels of potential harm when assembling or operating this device. NOTICE: Procedures which if not properly followed, create a possibility of physical property damage and little or no possibility of injury. CAUTION: Procedures which if not properly followed as described in this manual, create the probability of physical property damage and a possibility of serious injury.
Page 5: List Of Components
25 X M3x20mm C/S Torx bolts 1 X 6 Pin PCB bridge cable 25 X M3x10mm C/S Torx bolts 2 X 9 Pin BMS Balance cables 250mm of 6mm 3:1 heat shrink 84 x 21700 Cells are Required (Not included)
Page 6: Tools For Assembly
Tools for Assembly T10 Torx Screwdriver T10 Torx Bit ﬁtted to a Torque Wrench / Screwdriver 6mm Spanner Nitrile gloves Scissors Multimeter Isopropyl Alcohol Lint Free Wipes Ruler Blue Loctite 243 Micro USB Cable...
Page 7 Mechanical Assembly Steps It is HIGHLY recommended to ensure the area where assembly is taking place is clean and free of any small debris or dust. Before assembling please place a pair of nitrile gloves on to protect the terminals and contacts on the batteries or PCBs.
Page 8 2. Slide the lower PCB over the hex spacers until the PCB rests completely ﬂat on the base panel. If the PCB does not slide down easily, check the alignment of all the hex spacers and realign accordingly.
Page 9 3. Cut ﬁve 10mm lengths of heat shrink and place them over the four corner hex spacers and the centre hex spacer until they rest on the lower PCB.
Page 10 4. Using a lint free wipe and Ethanol or isopropanol alcohol, clean the battery contacts on the lower PCB. AVOID TOUCHING them afterwards and clean any contacts again if necessary.
Page 11 5. Slide one of the glass ﬁbre cell spacer panels over the hex spacers until the panel rests level on top of the heatshrink.
Page 12: Welcome To The 21700 Pcb Battery Pack Manual
6. Cut ﬁve 41mm lengths of heat shrink and place them over the four corner hex spacers and the centre hex spacer until they rest on the glass ﬁbre cell spacer panel.
Page 13: Contents
7. Slide the other glass ﬁbre cell spacer panel over the hex spacers until the panel rests level on top of the heatshrink.
Page 14 8. Cut ﬁve 10mm lengths of heat shrink and place them over the four corner hex spacers and the centre hex spacer until they rest on the glass ﬁbre cell spacer panel.
Page 15 9. Check the Voltage of all 84 21700 cells using a multimeter. The cells must be grouped into 12 groups of 7 cells of most equal voltages. All cells in each parallel group must have very similar Voltage - It is...
Page 16 10. Clean both the positive and negative terminals of all 84 cells using a lint free wipe and ethanol or isopropanol alcohol. AVOID TOUCHING the cells afterwards and clean any terminals again if necessary.
Page 17: Mechanical Assembly Steps
11. Check the polarity and locate the group positions labelled on the lower PCB, and insert the grouped cells into the assembly accordingly. Each group of 7 cells has the same polarity. Ensure each group of cells are facing the same way...
Page 18 12. After placing all the cells in position, double check the cell polarity is correct. Do this by comparing to the top PCB and checking all the cells row by row.
Page 19 13. Using a lint free wipe and ethanol or isopropanol alcohol, clean the battery contacts on the top PCB. AVOID TOUCHING the contacts afterwards and clean any contacts again if necessary.
Page 20 14. Place the upper PCB ﬁrst on top of the spring panel. You know when it is seated correctly as there will be none or minimal lateral movement.
Page 21 15. While holding the upper PCB and spring panel together, ﬂip them so that the upper PCB is facing down towards the top of the cells. CAUTION: Align the upper PCB & spring panel with the main assembly and proceed to place it directly on top of the cells. Make sure to align the top PCB panel &...
Page 22 16. Secure the PCB and spring panel to the assembly using the 21 remaining M3x20mm bolts with medium (blue) threadlock on and a T10 screwdriver bit ﬁtted to a torque wrench set to 0.65 N/m. Triple check that all 25 bolts have been tightened to 0.65 N/m by going up and down each row individually.
Page 23 17. WARNING: Make sure to 100% line up the male and female connectors in the correct orientation and location before establishing a ﬁnal connection! Follow the order in which the following instructions are written! Connect the PCB panels together ﬁrst plugging the 6 pin PCB bridge cable into the top followed...
Page 24 18. Connect XT90 extensions into the bottom PCB. Connect Male XT30 connector from (mounted on the spring panel) to the bottom PCB. 19. Connect the BMS Balance Cables into the BMS followed by the slots directly below on the bottom PCB. Connect the temperature cables from the top PCB to the BMS followed by the temperature cable...
Page 25 Congratulations, your cell pack is now assembled. Before the ﬁrst use, the pack should be allowed to balance all cells to the same charge level/voltage. You can manually start the balancing process in the VESC-Tool Software (See Next Section). If the cells are within 0.015V then balancing will not happen even if you start the process manually.
Page 26 VESC Tool This device may only be conﬁgured via the VESC-Tool! To start you’ll need to download the VESC Tool software on a platform you have available to you. Do not change any parameters unless you are 100% aware of the consequences. Use the latest ﬁrmware, delivered with the latest stable release of the VESC-Tool.
Page 27 Connecting the BMS to the VESC Tool Via USB 1. Open the latest desktop version of the VESC Tool. 2. Insert a MicroUSB cable into the port located on the BMS mounted to the underside of the spring panel.
Page 28 3. Open the VESC Tool to the start screen. BMS should now show up in the list of devices. Press the connect button to establish a connection. 4. Conﬁrmation that the BMS is connected to the VESC Tool can be seen by seeing the BMS under CAN-Devices, and also “Connected”...
Page 29 5. Enable BMS data by clicking the BMS icon on the right side of the screen.
Page 30 Cell Monitoring - Desktop Version 1. The cell group voltages can be monitored by clicking on the “BMS Data” tab on the left side of the screen. Here you can check how balanced the cells are and identify whether the cells are being balanced by the BMS. 2.
Page 31 Manual Cell Balancing - Desktop Version 1. Click on the “BMS Data” tab on the left side of the screen. 2. To enable manual balancing select the “BAL On” button in the bottom right of the screen. 3. Now check the cell voltages to verify that the cells are balancing. If the cells are within 0.015V then balancing will not happen even if you start the process manually.
Page 32 Connecting the BMS to VESC(s) The BMS should be connected via CANBUS to all of the VESC controller(s) used within your system. This enables the BMS to communicate with the VESC controllers and additionally enables NRF communication (if wired into your VESC controller) for convenient monitoring of the BMS data via the mobile versions of the VESC Tool.
Page 33 Conﬁguring the BMS and VESC(s) via Bluetooth 1. Ensure Bluetooth is enabled on your mobile device 2. Open the VESC Tool App on your device 3. Press “SCAN” if no devices are showing up 4. Press CONNECT” to then connect to the NRF The NRF can also be saved as a preferred device and renamed.
Page 34 Cell Monitoring & Balancing on the Mobile VESC Tool 1. Swipe horizontally across the screen until you reach the “BMS” tab at the top of the screen. 2. To enable manual balancing select the button with “...” in the bottom right of the screen.
Page 35: Vesc Tool
Discharge Settings The battery discharge settings need to be adjusted on all of the VESC(s) in accordance with the cell used. Use the following formula to calculate the correct “Battery Current Max” Setting: Single Drive: Max continuous cell discharge X 7 = Battery Current Max Twin Drive: Max continuous cell discharge X 3.5 = Battery Current Max Quad Drive:...
Page 36 Mobile Version Instructions are as follows: 1. Swipe horizontally across the screen until you reach the “MOTOR CFG” tab at the top of the screen. 2. Click on the second “General” tap and select “Current” from the dropdown list. 3. Scroll down the page and change the “Battery Current Max” to your calculated value.
Page 37: Battery Charging & Storage
Battery Charging & Storage Battery Warning Rechargeable Lithium-ion polymer batteries are potentially hazardous and can present a serious FIRE HAZARD, SERIOUS INJURY and/or PROPERTY DAMAGE if damaged, defective or improperly used. READ and UNDERSTAND the CHARGER MANUAL before proceeding. NEVER leave a battery charging unattended KEEP the battery away from children and pets NEVER charge a battery if it is damaged NEVER charge a battery if you are having problems or suspect something may be...
Page 38: Suitable Chargers
Suitable Chargers We highly recommend that you use either the 6A or 12A, 50.4V 12S LI ION BATTERY CHARGER pictured below and sold on our website. 6A Li-Ion Charger 12A Li-Ion Charger Alternative chargers can also be used. Please ensure you have read the manual for your speciﬁc charger and you are familiar with how to use the charger correctly before continuing.
Page 39: Charge Process
Charge Process 1. PLUG IN and TURN ON the CHARGER BEFORE connecting any batteries to the charger. 2. Remove the THUMB SCREW and INSPECTION PIT LID on the top of MONSTER BOX. 3. PLUG the XT30 EXTENSION from the charger into the XT30 inside the INSPECTION PIT.
Page 40: Maintenance
Maintenance Do not store the battery pack near ﬂammables or a built up environment. Always store the battery pack in a clean, dry, open space away from children and pets. After every 5-10 charge / discharge cycles, check the cell voltages to ensure they are still balanced.
Page 41: Li-Ion & Lipo Battery Care & Safety Information
Do not purchase lithium batteries before reading and understanding all of the safety precautions outlined in this section! Suitable Battery Cells The 21700 battery kit is designed for high discharge cells only. They have been tested with the following cells - use other cells at your own risk! Samsung INR2100-40T 4000mAh...
Page 42: Li-Ion & Lipo Battery Usage
With this in mind it is essential that you read carefully and fully understand the following information. Li-Ion & LiPo Battery Usage Procurement ● Purchase batteries from a reputable manufacturer or supplier. ● Avoid batteries shipped without protective packaging. ● Inspect batteries on receipt and safely dispose of damaged batteries.
Page 43: Discharging
● Do not parallel charge batteries of varying age and charge status; chargers cannot monitor the current of individual cells and initial voltage balancing can lead to high amperage, battery damage, and heat generation. Check voltage before parallel charging; all batteries should be within 0.5 Volts of each other. ●...
Page 44: What To Do In An Emergency
● Do not reverse polarity ● Do not insert insulation or other objects between the metal plate, cell or other components ● Do not overheat or overload ● Do not mix di erent battery brands or models ● Do not solder directly on the cell ●...
Page 45: Warranty Policy
Terms and Conditions. This policy sets out the Warranty Period and exclusions which apply to all products purchased from the Trampa Boards Ltd. website. This policy is subject to our Standard Terms and Conditions and should be read in conjunction with those terms, particularly clause 5 of the Terms and Conditions.
Page 46: Claim Procedure
For products purchased anywhere other than the Trampa Boards website, please revert back to your supplier. Service Work: Ad hoc repairs by Trampa Boards Ltd. are covered under Warranty for 30 days in relation to the original fault only. **Returns Policy...
Page 47: Contact
Saturday. Please remember if you are not in the UK then there is a time di erence to consider. Email: support@trampaboards.com Phone: 0044 7734 905883 Website: trampaboards.com Address: We DO NOT ACCEPT RETURNS without ﬁrst speaking with our customer support team. Trampa Boards Unit 16, Centre Court 33 Little Tennis Street Colwick, Nottingham NG2 4EL, United Kingdom...