Don't want to blow myself up...help someone please. Been stuck for months!

[ManxViking]

Hi all. I'm on a long journey trying to sort my lithium polymer pack from a Hyundai Ioniq.
I have been trying to get one 48v pack connected to my Daly bms but for some reason my bms gets warm on the connection very quickly.
I have connected to the bus bars that link each + to - through the pack but when I took a reading from the + of the bank to the - of the bms it wasn't showing 48v it showed 21.3?
I then tested each wire + to the negative and got results ranging from 4.04v to 36v and next was back to 8v.
Should the voltage be a steady amount that increases as I go along the connections? 4v then 8 then 12,16,20 and so on?
Does it matter in what order I connect the wires?
On the photo you can see on each bus bar link I used to connect the bms wires. Is this the right way to do it? ( I've removed the rivets in the photo) or should I be drilling into each + only side of the bar where it connects to the cell and not in between the + and - link?

Any advice gratefully received as I've been on this for months and as no one else I can find are using these batteries, I have totally nothing to use for a reference. Really hoping someone here can help.
If any more photos are needed please let me know.
Many thanks.
David

 

[sunshine_eggo]

I then tested each wire + to the negative and got results ranging from 4.04v to 36v and next was back to 8v.
Should the voltage be a steady amount that increases as I go along the connections? 4v then 8 then 12,16,20 and so on?

Yes.

Does it matter in what order I connect the wires?

Yes. Very much.

On the photo you can see on each bus bar link I used to connect the bms wires. Is this the right way to do it? ( I've removed the rivets in the photo) or should I be drilling into each + only side of the bar where it connects to the cell and not in between the + and - link?

No photo.

 

[ManxViking]

I have reconnected everything in order from the black wire then batt 1 then 2 etc.

 

[ManxViking]

When I test across the pack I get 49.3v. But if I plug in the balance wires to the bms and take the reading off the power cable I get 21.4v?

 

[sunshine_eggo]

BMS leads need to be connected in order. Black to (-), next wire to +3.7V, next wire to +7.4V, etc. If you fail to connect the leads in order, the BMS will be damaged or will not function as intended.

How many cells? 12?

Do you have a 12S BMS for 3.7V chemistry?

 

[ManxViking]

I have a 13s but seems it should be a 12s as the cells are 4v lithium polymer. I've connected in the correct order now but still no joy.
I've downloaded the pc program but it still doesn't recognise the BMS so I tried a second bms and still the same problem so it appears that the BMS is not turning on as both are in the same state.
I have looked on here for how to get the BMS working but as yet I have failed to find a way that will help me start the BMS.
It's probably something really simple but everything else is now correct except for the BMS not switching on.
Should I be putting the battery pack under load or trying to charge in order to activate the BMS?
Thanks.
David

 

[sunshine_eggo]

A 12S BMS has 13 sensing wires. If that's the case, you're fine. If you do not have a 12S 3.7V BMS, it won't work

To turn on a DALY, you:

BMS

If you want to know how to build your own battery, check out this page: Click Here If you need raw LiFePO4 Cells: Click Here

www.mobile-solarpower.com

 

[ManxViking]

Short the b- and p- when it's all connected?
I will try that. My bms is this type. Where does the last 13th red wire go then?
Many thanks
David

 

[sunshine_eggo]

Short the b- and p- when it's all connected?

Yes

I will try that. My bms is this type. Where does the last 13th red wire go then?

I count 14 holes in the connector.



Per the wiring diagram, the black goes on the main (-), and the 12th red (13th wire) goes on the (+) terminal. If you have a 13th red wire, you may have the wrong BMS.

 

[ManxViking]

Christ, hope I don't. I have 7 of these to cover the 7 packs I need to run!
13 red and 1 black wire. The last red goes to the main +?
I'll try that tomorrow morning.
Thanks, I've got further in 1 day than I have in months and decided I hate electrics ?? should have bought plug and play....

 

[sunshine_eggo]

Christ, hope I don't. I have 7 of these to cover the 7 packs I need to run!
13 red and 1 black wire. The last red goes to the main +?
I'll try that tomorrow morning.
Thanks, I've got further in 1 day than I have in months and decided I hate electrics ?? should have bought plug and play....

14 wires strongly suggests a 13S BMS. You need your battery and BMS Cell counts to be the same. What little I could find suggested your batteries are 12S. A 13S BMS will not work with a 12S battery.

 

[ManxViking]

I have had a chat with the sales rep from Daly. He spoke to the engineers.... He then reported back that the 13 and 12 and less bms just have the last connections linked and I can double up on the last battery in the pack.
I've done that but still only 21.3v from the BMS. I have tried all of the 7 I have with exactly the same result. Very much doubt they're all knackered.
Wondering if I wire up the hybrid inverter, to start charging that pack, the BMS would wake up. Any thoughts??
I have the right pc software, which still doesn't communicate with the BMS either.
Keeping going ?
David

 

[sunshine_eggo]

I have had a chat with the sales rep from Daly. He spoke to the engineers.... He then reported back that the 13 and 12 and less bms just have the last connections linked and I can double up on the last battery in the pack.

I may be wrong, but I don't believe this. This is the first time I've ever heard that's an option with the DALY dumb BMS. There are "flexible" BMS that permit use of a variable number of cells, but they tend to be "smart" and have to be configured via software.

I've done that but still only 21.3v from the BMS. I have tried all of the 7 I have with exactly the same result. Very much doubt they're all knackered.

Not knackered, but not the correct units for your battery. Did you try doubling up on the last cell and then "waking" it up by shorting P- and B-?

Wondering if I wire up the hybrid inverter, to start charging that pack, the BMS would wake up. Any thoughts??

You can try, but I bet at 21.3V, the inverter will refuse to charge it.

 

[ManxViking]

I have doubled the last cell, yes. I have also tried waking up the BMS by shorting the b- and p-.
Still no joy unfortunately. Might be stuffed but I've got this far so not giving up yet ?

 

[sunshine_eggo]

Again, I'm of the opinion that the claim you can "double up" and use a 13S BMS on a 12S batter is false.

IMHO, you have the wrong BMSs.

 

[ManxViking]

Just as an update for everyone. I've bought and now fitted the 12s bms's. All are working correctly and power up correctly. I've since bought a 5.5kw hybrid inverter charger which I have already wired in. Only last bit is 2 fold, 1 to connect to the already spare battery fuse on the solar setup ( solar guy did it in readiness for me to link in ) and then set the charging limits. Upper and lower voltage settings, which I am currently looking at ( seems to be 4.1v max to 3.6v min?) upper and lower settings.
Please feel free to correct me if I'm wrong.

Thanks to everyone who advised along the way. Now my Ioniq battery storage bank (38kw) is almost ready to actually start paying back some of the cost, and just in time by all accounts with these thieving British gas bods.
Fingers crossed it works well and as my overnight usage is so small, should cope really well.

David

 

[sunshine_eggo]

If you can live with the reduced capacity, NCM/NCM/LMO Lithium chemistry benefits greatly from restricting normal operating range between 3.50 and 3.92V. This is roughly 20-80% SoC.

 

[ManxViking]

Thank you very much for that info. A huge relief.
I can increase and push them slightly more through the 4 or 5 lower solar months and rest them through the summer as my overnight usage doesn't usually go over 8kw at night summer wise, winters about 18 to 20 at times.
Many thanks,
David

 

[ManxViking]

As an update, I've somehow managed to fry the inverter charger. Now states failure on soft start, error code 04.
Now looking for a repair shop

I was trying to configure the bms as stated previously and get the settings on the hybrid inverter setup but think I may have caused the inverter to pop..... I've attached the screenshot from 1 of the packs in case anyone has any idea.

Thanks.

David

 

[sunshine_eggo]

sum volt high protect 49.2 to equal 12 * 4.10V

diff volt protect 0.1. 0.8 is larger than your working range. Did you mean 0.08? That would be good too.

None of that should contribute to damage to the inverter/charger.