Sun Fun Kits V3 User manual

Sun Fun Kits V3, V3 Heated, & V3 RTB Assembly Manual
Revision 1.2

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:
● Electrical Safe Silicone sealant (for those looking to make a water resistant battery)
● Hot glue gun (if you wish to secure wires using this method)
Video Manual:
If you are more of a visual learner, you can view the build process on our official youtube
channel: https://youtu.be/tWm65Pu0GuI
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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 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 explained in this tutorial video:
https://www.youtube.com/watch?v=JGbZozzCYvM
NOTE: if you are using an RTB (ready to build kit) the active balancer will assist in top balancing
your cells, simply assemble your pack, charge the battery at 5-110 amps and within 1-2 hours
your cells should be even balanced. Again, certified cells that are included with your RTB kit will
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balance very quickly and the active balancer is included simply to assist balancing during high
amperage charging (over 80 amps).
Assembling your battery cells:
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 EPE 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.
PLEASE MAKE SURE TO PLACE CELLS CORRECTLY IN THE ORDER ABOVE.
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Heatead Kits:
If you are building a heated kit, you will have pre-installed silicon rubber heated elements
installed on your case, these will be joined to a t-plug.
The heated kits will provide additional resistance 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.
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Once your cells are in the correct position; it is now time to install your bottom bracket. With our
v3 kits we have made our cell bracket universal and it should fit virtually all cells in the 270-320
AH class. The one differentiating factor is cell height, these can vary from 200mm up to
205.25mm; to address this, the V3 includes 3 sets of shims, find the shim that best matches
your cell height to ensure a level surface.
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Install the bottom bracket with the M5 bolts and washers, you can use power tools to assist in
this step. NOTE: Ensure the negative and positive signs on the plate match your cells.
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The heated kits look similar to the regular v3 kits except they have a notch cut on the upper and
lower middle to allow the wires from the rubber heating elements to extruded into the main case.
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-150V2 4s
Bms, all wiring and prep has been done for you; simply bolt onto your components; no crimping
or cutting is necessary.
The V3 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 [email protected]
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Begin by aligning your buss bars as follows:
Now you will add your series terminals and BMS balancing/monitoring wires as well as the
active balancer wires (NOTE the initial negative post; and the final positive post are shared
between both the active balancer & BMS, all other posts may be separate for each cell) :
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