Install - side-by-side small cylindrical cell board, split bank

Installation and wiring instructions for split bank Cell Boards for multiple small cylindrical cells in series, mounted side-by-side

Warning.

Li-Ion batteries are dangerous!

• Wear safety glasses.
• Do not allow conductive objects (tools, solder...) to come into contact with cells or Cell Board
• Do not touch more than one battery connection at the same time

Good technique

Unfortunately, we do not have the resources to teach all of our clients proper assembly procedures, which are essential for a succesful project. What we can do is pass along this info to you:

• Proper tools
• Proper crimping technique from Molex

Naked battery preparation

It is assumed that:

• Cells are already joined together into a battery ("naked battery")
• Preferably, the cells are glued together to form a single, mechanically stable block
• Each set of cells in parallel cells is oriented up or down, alternating polarity
• Contact plates are already welded to the cells
• Contact plates include tabs that extend past the edge of the cells, for connection to the Cell Board
• Tabs are about 0.2" wide and extend about x 0.2" past the edge of the cells (5 x 5 mm)
• Each tab is lined-up with the centerline of its set of cells

Naked battery, ready for a Cell Board; straight (left) and mirror (right)

Cell Boards installation

• Preferably, rotate the naked battery upright, so that the tabs at the end of the contact plates are accessible
• Place the Cell Boards against the cells, keeping the tabs from touching the Cell Board:
  • The Positive End Cell Board at the most positive end of the battery
  • The Negative End Cell Board at the most negative end of the battery
  • The Mid-Bank Cell Board(s), if any, filling the remainder of the spots
• Orient the Cell Boards with the electronic components facing towards the cells (nested in the space between cells), and for the proper polarity:
  • Pad on Cell Board labeled 'B+' is located by the tab for the most positive end of that section of the battery
  • Pad on Cell Board labeled 'B01' is located by the tab between the most positive cell in that section and the next, more negative cell
  • Etc.
  • Pad on Cell Board labeled 'B-' is located by the tab for the most negative end of that section of the battery
• Fold and solder one tab at a time, in order, keeping the remaining tabs from touching the Cell Board
  • Fold the tab at the positive end of the battery down against the Cell Board; solder it to the pad labeled 'B+'
  • Fold the next tab down; solder it to the pad labeled 'B01'
  • Etc.
  • Fold the tab at the negative end of the battery down against the Cell Board; solder it to the pad labeled 'B-'
  • (You can also start at the 'B-' and work your way up to the 'B+' end)
• Once both tabs for a section are connected, the LED for that section will blink twice, repeated a total of 3 times
  • If the LED doesn't blink, please see the cell troubleshooting page

Battery with a Cell Boards; straight (left) and mirror (right)

Cell Board communication wires installation

• Measure and cut lengths of yellow wire to connect adjacent Cell Boards; If longer than 2" (50 mm) you may need to use shielded cable
• Strip each end of the yellow wire 1/4" (6 mm)
• Tin the ends of the yellow wires
• Tin the 'C-' and 'C+' pads on the Cell Boards, except for the 'C+' pad in the Positive End Cell Board, and the 'C-' pad in the Negative End Cell Board, and the
• Use a yellow wire to connect the 'C-' pad in the Positive End Cell Board to the 'C+' pad in the following (more negative) Cell Board
• Use a yellow wire to connect the 'C-' pad in the that second Cell Board to the 'C+' pad in the following (more negative) Cell Board
• Etc.
• Use a yellow wire to connect the 'C-' pad in the next to last Cell Board to the 'C+' pad in the Negative End Cell Board

Communication wire between Cell Boards; straight (left) and mirror (right)

Communications harness installation

• Install the batteries and the controller in their final positions in the battery pack
• Prepare the communication harness for this bank
• Plug the communication harness to the controller in the 'BANK 0' socket
• Connect the communication harness to the Cell Board:
  • If using plugs:
    • Plug the connector with red and black wires to the Positive End Cell Board, to the plug marked 'P1', near the positive end of the battery
    • Plug the connector with white and green wires to the Negative End Cell Board, to the plug marked 'P2', near the negative end of the battery
  • If not using plugs:
    • Solder the end with red and black wires to the Positive End Cell Board, to the pads marked 'P1', near the positive end of the battery: red to the round pad, black to the square pad
    • Solder the end with white and green wires to the Negative End Cell Board, to the pads marked 'P2', near the negative end of the battery: white to the round pad, green to the square pad

Communication cables added in; straight (left) and mirror (right)

Completion.

Repeat with the remaining banks, using the next available socket: 'BANK 1', 'BANK 2', etc. If using multiple batteries in parallel, see the banking page.