Sun Fun Kits V1 User manual

Sun Fun Kits V1 & V2 Assembly Manual
www.sunfunkits.com
Revision 1.01

Before you Begin:
Thank you for purchasing your Sun Fun Kits DIY battery kit, the diy battery kits makes
assembling your battery quick and easy and only requires basic tools and hardware. We
recommend having a basic understanding of DC wiring in order to assemble your battery pack.
You will 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:
● Silicone sealer (for those looking to make a water resistant battery)
● Hot glue gun (if you wish to secure wires using this method)
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Preparing your battery cells:
Sun Fun Kits DIY battery kits support various prismatic cells, in this manual we will be using the
EVE 280N type, however the process is the same for other manufacturers such as CATL,
RCPT, and more, be sure to select the correct cell type when purchasing your kit.
Before you can begin organizing your battery pack, you will need to perform a TOP BALANCE
of your battery cells. This process requires you to charge your cells in parallel, meaning you will
join the positive terminal of all your cells into a single circuit and your negative terminals into a
single circuit.
This process is explained in this tutorial video:
https://www.youtube.com/watch?v=JGbZozzCYvM
Assembling your battery cells:
After you have completed top balancing, it is now time to begin battery assembly. Begin by
placing your cells in a series configuration with the left side of the battery having the positive
terminal on the lower left and the negative terminal on the lower right.
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Note: you may find some resistance installing your cells, this is because the EPO foam exerts
pressure on the cells to keep them in place. We recommend adding the left most and right most
cells first and then adding the remaining 2 inner cells in the end.
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PLEASE MAKE SURE TO PLACE CELLS CORRECTLY IN THE ORDER ABOVE.
Once your cells in the correct position, it is now time to install your bottom bracket, this will vary
depending on the option you select when purchasing your kit, generally the v1 kit have the
bracket that is optimized for the EVE 280N with drilled holes, while the V2 kit is designed for
various cells and can also support the EVE 280N with drilled or welded studs.
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Install the bottom bracket with the M5 bolts and washers, you can use power tools to assist in
this step.
After the bottom bracket is installed, you will now need to add thread locker to your terminals (if
using drilled terminals)
Setting Up Electronics & Cell wiring:
This step involves wiring up your cells, you will need a BMS system and optionally a
supplementary balancing device to complete this step. You will also need to have the
appropriate wiring done to complete the electrical setup. If you are using our SFK-150 4s Bms,
all wiring and prep has been done for you and simply requires you to screw in your components.
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Begin by aligning your buss bars as follows:
Now you will begin by adding your series terminals and BMS balancing/monitoring wires:
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Sun Fun Kits include 6mm bolts that are 8mm in length; these will fit the drilled EVE 280N cells
properly and will ensure a proper fit. Our BMS also includes correct sized terminals that fit 6mm
threads/blots properly.
You will need to ensure a tight fit, take care not to strip your battery terminals, if you are using a
torque wrench you will want to tighten down to 6-8 NM. WARNING LOOSE terminals will
cause the cells & batteries to fail.
The writing schematic should be as follows:
black wire = cell 1 negative
1st white wire = cell 1 positive
2nd white wire = cell 2 positive
3rd white wire = cell 3 positive
red wire = cell 4 positive
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Your voltages should read:
3.6, 7.2, 10.8,14.4 (if the battery cells were full during the install).
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 multiple devices. Make sure the
wired main terminals are the ones that touch the cell terminal and only stack the other rings
on top.
Once you have verified the wiring has been installed correctly, you can now begin by attaching
the top plate & your BMS.
V1 & V2 difference:
Both the V1 and V2 kit are essentially the same with the major difference being that the v2 kit
can accommodate taller cells and cells with welded studs by incorporating a spacer and internal
riser design.
V1 kits will allow you to simply install your top plate directly on top of the bottom plate as shown:
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The v2 kits allow for a spacer to be incorporated:
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