I made a pcb board for the balance taps using a DB25 pin connector as posted earlier. The connector will be mounted onto the shell, but set back. I will use a cover to protect it from dirt. The wiring took some time to plan out. I will be cutting up one of the DB25 boards to create a harness out of it using cables purchased from EP buddy to simplify the wiring build. This will keep things simple. I'll post details as it comes along.
EP buddy does sell a 6 to 1 balance connector, but it would not be ideal due to the various locations of the packs. I will be creating a modified harness by cutting up harnesses purchase from them and mixing it with my chopped up DB25 circuit board. I won't charge this setup without balance taps, due to the way it's setup. I won't have the luxury of removing the packs for charging so I need to make sure every charge cycle is error free. The carbon fiber cover will be used to prevent any fire incase there is a problem. Once the covers are on, visual inspection won't be possible. Due to the harsh trail riding conditions, my biggest concern is a structural error due to connectors rubbing into the packs, connections coming loose, or possible friction. I should of covered each pack with a layer of tape, but this didn't occur to me till I was already securing the packs into the frame. I will however wrap tape around it before I secure the wires and perhaps fill any spaces with hot glue or silicone to maintain the small distances between packs. Last thing I want is a pack to shift from a hard jump and slowly grind itself open overtime. It's pretty secure now with double stick tape and kevlar straps. Anything can happen overtime though.
The hyperion won't have any problem charging large packs. It protects itself, limiting any excess. It's the power supply that will have the most difficult time of it. Sounds like you are set with your power supply.
shock wrote:Awesome, looking forward to seeing the wiring, as this was the most difficult part in my opinion. So you do plan on charging that entire array 12c6p, at the same time with the 1420i. I planned to charge my 12c5p all at once, just wanted to make sure I'm not overloading the hyperion. I'm currently building a 24v 575w power supply using HP server supplies. Are you going to hardwire the balance taps? Or make a PCB for them or something? Can't wait to check this bike out!!