Sun Fun Kits V3.5 Assembly Manual Download | Manualshive

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Sun Fun Kits V3.5 Assembly Manual

Revision 1.2

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Summary of Contents for V3.5

Page 1: ...Sun Fun Kits V3 5 Assembly Manual Revision 1 2 ...

Page 2: ...ll also need the following tools Hex driver set 3mm 4mm 5mm and 8mm Insulated drives for securing bolts Thread locking compound such as blue Loctite Kapton tape 1 to 2 in width Double Sided Sticky tape Velcro style loop DC Voltmeter DC Power Supply that is able to charge up battery cells 3 65 volts 20 Amps Optional Electrical Safe Silicone sealant for those looking to make a water resistant batter...

Page 3: ... be using the EVE LF304 type however the process is the same for other manufacturers such as CATL REPT Ganfeng and more the V3 Kit includes spacers and other items to ensure maximum compatibility for cells in this class 270 320 AH Certified Automotive Grade Cells generally do not require balancing however you may choose to balance your cells we have a video explaining this process This process is ...

Page 4: ...ist balancing during high amperage charging over 80 amps Assembling your battery cells Starting with version 3 5 we are now including different cell shims or spacers this allows users to have a nice tight fit while also adding a third layer of insulation between cells Version 3 5 includes 1 set of 1 5mm and 1 0mm shims 3 pieces each The shims should be placed between the inner cells and most insta...

Page 5: ...ur kit This provides good heating and will raise the inside temperature of your case evenly This method is quite easy to install and is the only method that should be used if you are using grade B cells or swollen cells as it provides the most amount of spacing for the cells Begin by placing your cells in a series configuration with the left side of the battery having the positive terminal on the ...

Page 6: ... want to have the textured side of the shim facing the cell you installed with the smooth side facing the empty space This will ensure the shim stays in place while you install cells Page 6 V3 5 Manual Revision 1 2 ...

Page 7: ...then adding the remaining 2 inner cells in the end as shown in the illustrations above PLEASE MAKE SURE TO PLACE CELLS CORRECTLY IN THE ORDER ABOVE V3 5 kits support various cells and depending on your cell height you may or may not need cell spacers For LF280K and LF304 cells sold by Sun Fun Kits you will use the 4mm spacer on top of the aluminum braces to raise the height of the support so that ...

Page 8: ...sistance to cells when they are being installed however there is still sufficient space to insert the cells It is recommended that you do not install fully charged cells as they will make the process challenging Page 8 V3 5 Manual Revision 1 2 ...

Page 9: ...ires from the rubber heating elements which provide a channel for the wires into the main battery assembly Setting up heating using heated cell separators advanced The cell separator option is the more advanced heating option available in version 3 5 kits this allows 2 cells to be heated by a single silicon rubber heating element 2 elements in total are able to heat all 4 cells The direct contact ...

Page 10: ...olyester BASED is required to handle the heat being generated by the silicone pads Once attached you will be able to place this into your battery case note in this case there are no heating elements on the sides of the case walls As with the non heated kits place the leftmost and rightmost cell first ensuring they have the correct polarity before installing Page 10 V3 5 Manual Revision 1 2 ...

Page 11: ...ator for the kit you can select from either the 1 0m or the 1 5mm shim depending on how tight you want your install to be the tighter the better for most installations The textured side of the shim should be facing the cell while the smooth side should be exposed Page 11 V3 5 Manual Revision 1 2 ...

Page 12: ... 2 heating pads and 1 shim now you can place the cells spacers shown above as the green pieces that sit on top of the aluminum brackets and proceed with mounting the V3 5 main plate note the cell spacers are needed for cells that are 204mm or taller if you have 200mm tall cells you do no need to add the cell spacers on Route the heated cell separators through the dedicated slots on the v3 5 kit Pa...

Page 13: ...rminal this will go to the positive lug on the case and 1 wire from each pad to the black terminal this will go to the heater port on the BMS DO NOT CRIMP BOTH wires of the same pad together it will not complete the circuit Which wires you chose does not matter as long as the wires being crimped are not from the same pad Page 13 V3 5 Manual Revision 1 2 ...

Page 14: ...ical setup If you are using our SFK 200V2 4s Bms all wiring and prep has been done for you simply bolt onto your components no crimping or cutting is necessary The V3 5 kit system supports various BMS devices from manufacturers such as JBD SFK Series Daly Ant QUCC and more New device support is being added constantly if you need a specific mounting plate made simply contact Sun Fun Kits support at...

Page 15: ...Begin by aligning your buss bars as follows Page 15 V3 5 Manual Revision 1 2 ...

Page 16: ...nsider covering this terminal with kapton tape or other insulating material to ensure that it can not short circuit the first cell NOTE be sure to use the included washers for the BMS and Active balancer terminals A washer should be placed above each bus bar and optionally above it For version 3 5 we are now including M8 Nylon Lock nuts as they provide excellent anti vibration capabilities without...

Page 17: ...Volts The 1st white wire is the wire that is right next to the black wire the subsequent wires will be white wire 2 and white wire 3 The active balancer should be wired black wire cell 1 negative 0 00 Volts green wire cell 1 positive cell 2 negative bus bar either post may be used 3 3 Volts yellow wire cell 2 positive cell 3 negative bus bar either post may be used 6 6 Volts white wire cell 3 posi...

Page 18: ...d 3 3 6 6 9 9 13 2 Nominal Voltage If you are using a supplementary balance you should install this as well you will need to share the final negative and positive terminals of the battery for the bms and the supplementary balancer Make sure the wired main lugs are the ones that touch the cell terminal and only stack the other bms and active balancer rings on top Page 18 V3 5 Manual Revision 1 2 ...

Page 19: ...gin by attaching the top plate your BMS Installing riser and BMS mounting plates After you have verified that your cells are mounted correctly AND VERIFIED they have correct voltage readings you can now begin mounting the BMS and other related electronics Being by mounting the riser plate by first inserting the active balancer connector into the balancing unit and then rotate it so that it matches...

Page 20: ...ted kits will power the silicon rubber heating elements either form dedicated ports on the BMS Starting with Version 3 5 we will be exclusively using BMS based heating as based on your user feedback this is the preferred method most users want The SFK 200 V2 BMS is an excellent choice for this as it has a dedicated heating port that is activated during low temperature charging Page 20 V3 5 Manual ...

Page 21: ...For heated kits it is recommended to use kapton tape to secure the wires and flap of the silicon rubber heating elements to the sides of the riser plate Page 21 V3 5 Manual Revision 1 2 ...

Page 22: ...all the m4x15 25 mm bolts on the bottom and the m4x15mm bolts on the top NOTE Make sure the balancing lead is NOT connected to the BMS This will be inserted in a later step Page 22 V3 5 Manual Revision 1 2 ...

Page 23: ...e BMS and or thermal switch you are using For most BMS units you will attach the positive to the main battery terminal post on the lid followed by the negative terminal which is connected to the output port of the BMS NOTE it is extremely important that you do not hook up the thermal switch or silicone heater pads directly to the posts on your cells this will by pass your BMS which may cause your ...

Page 24: ... default safer option are the flanged top bolts as they make loose terminal bolts impossible while also providing a height benefit as they are about one inch shorter Once you have determined your mounting preference take your preferred mounting option and attach your top lid Page 24 V3 5 Manual Revision 1 2 ...

Page 25: ...rque setting appx 110 inch lbs Heated kits shall attach the positive terminal of the thermal switch silicone heater terminal to the final post on the lid NOTE be sure that the heater terminal sits ABOVE THE MAIN LUG it should never be below it as this will result in a poor connection resulting in a high resistance connection and will cause damage to your battery Page 25 V3 5 Manual Revision 1 2 ...

Page 26: ...op lid using the 4x15mm countersunk screws USE HAND TOOLS No Impact Drivers for this step Optionally if you would like to have a moisture water resistant seal you can use electrical safe silicone low order sealant between the lid and the lip of the battery A good example is this brand Page 26 V3 5 Manual Revision 1 2 ...

Page 27: ...ess shown on a v1 kit https www youtube com watch v g7AIX0kE1Lw The last step in your kit assembly is to attach the handles grips This process is very simple thread the nylon rope through the plastic barrel and through the hole on the kit handles Page 27 V3 5 Manual Revision 1 2 ...

Page 28: ...Once through simply insert the nylon barrel into the built in latch using a flat head screwdriver Once done your kit is now complete and ready for testing Page 28 V3 5 Manual Revision 1 2 ...

Page 29: ... perform tests visit Google Play Store or Apple IOS App store and search for Sun Fun Kits BMS https play google com store apps details id com companyname sfkble hl en gl US https apps apple com tt app sun fun kits bms id1600445506 Page 29 V3 5 Manual Revision 1 2 ...

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