Zippy Flightmax !

September 1 - 2011


6 x 6S 5ah Zippy 25C packs.

Will assemble into 15ah ( 3P ) and 48v ( 12S )

All 6 packs arrived in good conditions, all cells 3.8x volts

Hyperion ESO1 1420i charger

Most low end RC chargers do up to 6 cells, the better one's do up to 10 cells, this bad boy does up to 14 !!! so a 48v pack can be charged all at the same time, no flipping wires and messing splitting packs to charge up.. !

Left Side : USB port and Temp port..

Right side.

Rear, dual fans !!!.. bonus !

And they run quiet ! Unlike the crappy Turnigy 4x6 charger that sounds like it's going to take flight..

Front, A and B ballance ports, and an NET ( network ) port to allow multiple chargers to be connected for higher voltage packs !

Next up : goodies provided by Ggoodrum ! ( Who also provided the Hyperion charger )

2 items here..

And the Dual 6-Channel ( 12s4p ) Low-Voltage Cutoff ( LVC ) Parallel Adapter v 4.3.4 ( 2 March 2011 )

First is the Hyperion EOS 1420i Net3 12S Charging Harness Kit v4.3.4 ( 9 March 2011 )

I had the option to get the boards and a bag of parts to solder my own, but honestly i'd much rather pay the man to do it right, one of these days i'll have a tutorial for people like me on how to do this right but until i have the time to do it right, i'd rather have it done for me hehe.. besides .. it's september and if i mess it up and have to order more parts.. then have to figure out how to troubleshoot what i screwed up etc.... no thanks.

Next step, clear the workspace, always very important to work on batteries in a clean area, even tho it becomes a rats nest within no time of starting a project, try to always start on a non-cluttered desk..

Here we go !

First step is to power up the Hyperion charger, and individually ballance charge each pack on their own..

Dug up a 12v compaq power supply, and the Hyperion came to life ! woohoo !

The menu is different from my Icharger 3010B , it's all there but not as easy to figure out, i had to hit up youtube

I charged 2 packs via the Hyperion, the other 4 being very well ballanced and in near exact state of charge ( SOC ) .. i put them in series and bulk charging on my 100v Chaos charger

The HK battery medics are not very accurate but good enough to keep an eye on things..

4 of the 6 packs in series = 100v !

Cycle 1 on the LBD ! ( Light Bulb Discharger *tm

Visual on all 24 cells, no time to go for a walk, this is where you stay nearby and avoid distractions...

Discharge 5ah at roughly 5 amps = under 1 hour cycle... *( 1C )

So kitchen timer/ringer set to 35 minutes.. just in case...

I am 4ft away at my PC, but in the event i walk away for any reason, i need to make absolutely sure i remember to come back

3.2ah .. so far so good.


And at 4.6ah i terminated the cycle while all cells were at 3.6x volts, no doubt they would deliver the full 5ah but i do not want to push them that far... this is good enough to eliminate the possibility of runts.

After reading the instructions, ( Very well done instructions btw, full color, and specific.. ) a few times over, from start to end.. yeah.. all the way to the end BEFORE starting the assembly.

I got it thru my mind how it goes, and fired up the Hakko soldering station.

One thing i've learned over the years, setup your wires the way you want them before you start soldering.. makes the final product look way better..

Other side.

Pins 1 and 2 are taken by the negative charge circuit, then the ballance wires start on pin 3 ..

After soldering all the charger side wires..

I moved on to the battery pack side of the multi pin connector.

Something you learn from playing with andersons, orient your wires and setup the pins so that the wire will not twist, i had to put the charger side block onto the desk, look at the receiving end connector for 5 minutes and get it right thy mu thick skull how things will end up... and this is how it goes..

The pins slide into the blocks with 2 grooves, pay close attention, if you get half one way the others wrong, it will work but look wonky.. so pay attention..

Now, i'm sure there is a fancy crimping tool for these pins, but i dont have one... so after mucking about with needle nose pliers for the first 2 i went digging thru my tool collection and found that my Gardner Bender vice tool will bend the legs in the right direction to get things started..

The first 2 legs ( as far as i can figure out ) shoudl clamp down on the insulation part of the wires, the 2nd pair is the contact part, the 3rd set is what lines up with the plastic housing..

Bending the first pair legs inwards lets you pinch them with needle nose pliers and maintain a square block so that it all fits into the connector block.

Then i hit them with the soldering iron, just enough to insure proper contact and prevent the pins from ever pulling out..

Be carefull here to orient the pins vertial so that you prevent solder from creeking into the tips, this would make the thing hard to connect, and harder to disconnect.. done right it should snap in easily.. dont want solder up there.. keep it in the red.

after crimping and soldering, drive them on home with a tiny flat head screwdriver..

The battery side harness needs pins 1 and 2 ( negative ) split in 2 from a 14 awg wire.. same for the positive side.


it's not easy stuffing half a 14 awg wire into one of thes pins.... but i got it done !!!

crimped and soldered !!!

I cut up some self-stick floor tiles left over from this project :

And added double sided tape to the other side so all the packs are stuck together.

Voila !

Put together and gave them the gentle squeeze to square up the pack.. 160 mm !

bad lighting, but there she be.. a 6 pack of lipo !

All charged and ballanced..

Next step is to cut all those bullets and install andersons ... i wish i had a bag of these connectors, would save a lot of work.

Then i box this inside an ABS layer


Bullets removed and andersons installed, i made the main Positive and Negative parallel power cables, they are 3 x 12 gauge wire, one from each of the 3 " A " packs, with a 14 gauge wire for the charger, and a 10 gauge wire for the discharge ( controller side ) ..

Next was to figure out what to do about the mid point connections, i could hook them up as shown below..


We had a discussion about this on the sphere HERE !!

And at first i decided to make parallel harnesses

Above, i cut 2 short pieces of 12 gauge wire, and removed a section of silicone from the middle longer wire..

Then banded the 3 wires with a piece of copper, and soldered the whole thing together !

Getting crowded in here..


It always starts off nice and neat, but as you finish up the rat's nest grows ever larger...

I covered the LVC board with pvc tape, not sure if it gets hot but as it does not bleed power and leaves the ballancing up to the charger, i assume there will be minimal heat buildup on it..

Notice how the workspace gets clutterd !!!!

Hot Glued all exposed metal pins ( Still have to cover the LVC A / B board connectors too ) ..

And under

Next up, the fun part, drop this into a backpack and go for a test ride !!!


Sep 10, 2011

Cut and bent some 1/4" ABS plastic, drilled holes for the wires, hot glued the pack to the ABS and wrapped a few layers of tape behind the wires with glue so that when the wires get tugged they dont come un-done from the parallel harnesses.....

On the charger for a top-off...

put a CA between the charger and power supply...

13.2 Lbs !!!

120 x 175 x 195 mm

Done !

Battery, Meet bike ( i need a picture of the bike hehe )

Sep 16 , 2011

Well now.. imagine this... i just got off the phone with Mr.B and aparently.. somehow... upon connection of the new pack to the controller, the andersons vaporized into plasma and caught fire !!!!!!

I installed a 70 amp fuse prior to the pack leaving here and the fuse did not pop, Mr B. swears the polarity was right...

Having him bring the bike and pack back here tomorrow for further investigation but i'm at a totall loss to explain what the hell happened... i have connected 1000's of times various anderson assemblies from 12 to 100v and have NEVER had this happen... i've had them stick and spot weld themselves a few times but a few wiggles and they snap in place but never any fireworks... ever...


Next day....

Say hello to Mr. Crispy

After investigating the remains i determine that it was an accident on the new guy's part !

Impossible to tell via the tips of the andersons, they are gonners, but the box ends of the powerpoles are still there and i can tell that with male sides facing up on both ends, it would be impossible to make a proper connection, so they were plugged in reverse polarity !!!

Cut the charred pieces away and re-crimped new andersons, tested the pack and everything is ok !

I canot figure out how the controller did not blow up but it did not..

Over a month later now, ( oct 21 , 2011 today ) and the pack and the bike are running well !


March 30, 2012

Late january or so, i asked Mr.B to bring the pack back here for a winter checkup, and to remove the circuit board from the packs in parallel..

All 6 packs are showing 3.99 to 3.98 , canot ask for any better than that..

Connected the BMS back up, closed up the box, ran a few shallow cycles and she's ready to go !

Above, Mr.B's bike, an old school CCM, rear 9C with 35 amp controller..

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