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Companion board development
Instead of designing a whole new BMS, we just designed a companion board that communicates to the bicycle controller and handles the LEDs.
Golf cart
Documentation for the golf cart batteries made by Battkomp AS in 2022-2023 using second life VW e-Golf battery modules.
Companion board development
This project was a commercial failure, but we did get a pretty good companion board going in the end. The software and production files are available on GitHub: https://github.com/gregyedlik/Yamaha-BMS-companion
Bill of materials
Quantity Price per unit w/o MVA VW e-Golf big module 3 2000 Daly 12S 80A BMS, Smart w/ BT 1 700 VW connector 3 10 VW connector pin 13 3 Board, cut and pai...
Prototype building
Cleaning Building The 2nd generation VW modules The smart modules do not show the voltages. It is possible to install a dumb board instead, but need to drill it to be able to screw it in. Pinout of the 10-pin orange connector: 1 T...
BH Emotion batteries
BH Easy Motion 36V and 48V batteries: BMS design, repair, and rebuild guiides
Plugs
The original chargers used the Lester 21486 connector. This connector has three pins, and is really smart: Positive Negative Charge enable - AND IT IS SHORTER!!! That way it will only charge if the connector is properly in. It plugs in under t...
Yamaha e-bike batteries
Designing a compatible BMS solution
Cutting the main boards
The main boards were made of 18mm thick pine boards cut on a CNC mill at Fellesverkstedet. Painted to conserve. Design Implementation
BMS settings
The BMS is a Daly Smart BMS with Bluetooth, Li-ion 12S 80A. One must connect to the BMS via the smartphone app to set the settings and enable the BMS. To be able to connect, you might need to press the button on the bluetooth puck first: It is located on...
General knowhow
Some notes for myself or for my colleagues that might benefit you too! :)
Troubleshooting
You find yourself with one of these batteries and it just doesn't work? Let's go step by step. You will need a smartphone, a multimeter, and a paper notebook to take notes of the steps and measurements you take. The battery must be worked on with a feeling of ...
E-bike battery guides
Repairs, recells, little tricks we learned along the way.
Shimano BT-E60xx and BT-E80xx
How to repair fuses, how to swap connectors, how to make custom chargers, and how to discharge.
Bosch PowerPacks
First and second generation, recell, CAN communication, chargers
Other batteries
Pallet jacks, chainsaw, surf board, scooter...
Concept
Problem The car originally had 6 pcs of 8V deep cycle lead acid batteries: Trojan T875. They are 170Ah nominal capacity wet batteries. Apparently the size is a standard for golf carts: BCI Group Size: GC2 - Dimensions: Length: 10.27” (261mm); Width: 7.10” (1...
VW e-Golf modules, 2nd generation, 111 Ah
Small module Pinout: B1 = pin 7 B2 = pin 3 Temp1 = pin 6 Temp 2 = pin 1 There is no ground, no B-!!! Big smart module The big modules also have just one temperature sensor. The one I saw had 3 connectors: One black towards temp sensors One ...