DIY E-bike Battery || Assembling 48V Hailong Battery

Intro: DIY E-bike Battery || Assembling 48V Hailong Battery

Hello, fellow makers!

In this instructables i will add extra insights for my tutotial on how to assemble a Hailong battery(48v) for E-bike battery.

BE SURE TO CHECK OUT THE VIDEO FOR THE ASSEMBLING PROCESS.

And if you want more details you can see my instagram handle @hyper_makes

Happy Making!

STEP 1: Parts and Supplies

I AM PROVIDING THE LINKS TO THE PARTS AND THINGS I USED ** WHICH ARE NOT AFFILIATED**

Hailong 48V Battery case : HERE

18650 Li-ion cells EV grade 3C discharge rate : Local supplier

54.6V 4A Charger : HERE

Spot Welder : HERE

BMS(13S 60A) : BE SURE TO CHECK THICCNESS BEFORE ORDERING HERE

Silicone Wires : HERE

Insulation Gasket : HERE

TOOLS REQUIRED :

Soldering Iron

Solder wire

Solder flux

Hot glue gun

Wire stripper

Kapton Tape

STEP 2: **BE SURE TO CHECK THE THICCNESS OF BMS AND SET SPOT WELDER TO CORRECT MODE**

Before you order your BMS(Battery management system) circuit be sure to check its thiccness because there is very little space inside the case.

ALSO CHECK YOUR MOTOR CONTROLLER FOR MAX CURRENT OUTPUT. MINE HAS 45A(MAX) CURRENT RATING SO, THE NEAREST BMS I FOUND HAS 60A(MAX) OUTPUT.

**ALSO THE BMS CONNECTING WIRES SHOULD BE SOLDERED FIRST TO THE NICKEL SHEETS BEFORE WELDING THE SHEETS TO CELLS.**

SPOT WELDER SHOULD BE SET TO 300 MILLI SECONDS MODE FOR GOOD WELDING JOINT.

STEP 3: SEEK AND FOLLOW CORRECT WELDING DIAGRAM

Follow the correct welding diagram given with the battery kit. IF NOT THEN GOOGLE ABOUT YOUR BATTERY CONFIGURATION AND FIND CORRECT DIAGRAM. EXAMPLE IN MY CASE : 13S5P CONNECTION DIAGRAM.

STEP 4: MASK THE BATTERY PROPERLY BEFORE ASSEMBLING

Mask the battery properly so that it is safe from any kinds of short circuits and accidental shorts.

IMPROPER MASKING OF BATTERY CAN LEAD TO FIRE ACCIDENTS AND DEAD BATTERY.

STEP 5: WIRE ACCORDING TO DIAGRAM PROVIDED WITH KIT OR GOOGLE AND THEN DO THE FINAL ASSEMBLY

Do the wiring according to the diagram provided with kit you bought or google about it.

THE PHOTOS I HAVE PROVIDED ARE JUST COMMON EXAMPLES ON HOW TO DO WIRING AND CONNECTION.**PLEASE CHECK IT WITH YOUR BMS AND BATTERY IF YOU ARE GOING TO FOLLOW!**

Snugly fit all the wires at the edges of the case so that you can close the lid of the case properly.

Hot glue wires in place for more secure fit.(If necessary)

That's it. You have assembled your own e-bike battery. Check video if you are stuck somewhere.

STILL IF YOU HAVE ANY KIND OF QUESTIONS, BE SURE TO COMMENT DOWN BELOW. I WILL TRY MY BEST TO HELP YOU OUT. :)

Happy making!

STEP 6: Update:Do Not Use Switch Provided in Battery Case!

The switch provided in the battery case is rated for AC applications only and can't handle large currents for DC applications, thus making it a potential bottleneck for the current flow. The switch **can burn easily** in this high current application when you will use the hub motor at full power.

SO I RECOMMEND NOT TO USE THE SWITCH IN WIRING THE OUTPUT WIRES. IF YOU HAVE ALREADY WIRED THEN YOU CAN SIMPLY SHORT THE THE PINS WITH 12AWG WIRES TO BRIDGE IT.

Comments

[medicpg]

I appreciate your Tutorial. Do you have a image of all the packs and the numbers. I can slow down the video and see one side but the other side is not as clearly shown.

[Praskavi]

Hi, Thanks for the tutorial, wondering if you can provide the wiring/connections instructions to battery level indicator display. It will be very helpful if you can also share how we can connect the usb port of the hailong case. I understand we need with step down usb module.Appriciate your response.

[roberto.vanmaanen]

for safety and sake of completeness you might want to add a fuse. for a 500w motor a fuse of 20a or 30a would be sufficient. get a (car) fuse and fuse holder. also i would advice to use 12 awg (20a) or 10 awg (30a) cable, i dont see you state wire thickness in the article. thanks for your great guide, it helped me build my pack.

[hyper_makes]

Yes! You are right. A fuse would a very good extra safety feature. Pardon me, i have not mentioned anywhere in the article but i have used 12 awg cable for connections indeed. Glad to hear i could help you.

[marceloscorner]

Hello,
First I would like to thank you for the tutorial !
I’m surprised that you mention not to use the included ACC ON/OFF switch that comes with the case.
I have followed my case supplier instructions that says that to use with we must buy a BMS with pre wired ON/OFF.
So the included ACC ON/OFF do not cut the main power but just the BMS electronic ON/OFF.
I can understand that in your case if you have note the proper BMS you must avoid to use the switch.
Best regards,
Marcelo

[roberto.vanmaanen]

Here is a good forum post that explains how you can solve the ac switch issue:
https://endless-sphere.com/forums/viewtopic.php?t=....

Basically they add an extra switch with a resistor to slowly charge first ( to fill the capacitors) then use the main ac switch to fully switch on. So it would require you having to turn on two switches each time.
What you could better do imho is adding a maritime switch with a high amps rating (over 100a). This switch should work fine on its own:
https://www.amazon.com/NSTART-Isolator-Disconnect-Selector-Vehicles/dp/B08Y5TFBJH/ref=pd_rhf_dp_p_img_1?_encoding=UTF8&psc=1&refRID=NYSFJH8RXB3PKW84X2D4

[hyper_makes]

Appreciate your support <3. Glad I could help you.