Perhaps some of the members of this forum would find my recent build to be interesting.
I ordered a group of eight 22.2v nominal (6s) 4Ah batteries and bundled them into two groups of 4. Each group of 4 has two 30A fuses that connect them to both pairs of the contacts in one Speakon connector in the ammo box. The ammo box also has a 7-pin XLR connector for each group of 4 to connect the balance conductors. The resulting box has two Speakon connectors with 4 pairs of 22.2v connectors.
I made a cable for the balance conductors from three braided Cat-5 UTP cables that use 24awg conductors. Each pin on the balancing conductors gets 3 conductors which works out to a bit better than 18awg per pin. Each pin in the Speakon main charging cable uses 6 [corrected from 8] 24awg conductors which works out to around 14awg conductors.
The junction box in front puts the two Speakon connectors in series for the 48v Infineon controller. It has a 30A fuse and a 50A on-off switch connected to the controller. When this same ammo box is installed on my Cyclone bike (currently being re-built), the junction box on the Cyclone will parallel the Speakon connectors to provide 24v to the controller/motor. Therefore, no changes to the internals of the ammo box, nor any changes to the charging setup are required.
Pictures below.View attachment 3
I ordered a group of eight 22.2v nominal (6s) 4Ah batteries and bundled them into two groups of 4. Each group of 4 has two 30A fuses that connect them to both pairs of the contacts in one Speakon connector in the ammo box. The ammo box also has a 7-pin XLR connector for each group of 4 to connect the balance conductors. The resulting box has two Speakon connectors with 4 pairs of 22.2v connectors.
I made a cable for the balance conductors from three braided Cat-5 UTP cables that use 24awg conductors. Each pin on the balancing conductors gets 3 conductors which works out to a bit better than 18awg per pin. Each pin in the Speakon main charging cable uses 6 [corrected from 8] 24awg conductors which works out to around 14awg conductors.
The junction box in front puts the two Speakon connectors in series for the 48v Infineon controller. It has a 30A fuse and a 50A on-off switch connected to the controller. When this same ammo box is installed on my Cyclone bike (currently being re-built), the junction box on the Cyclone will parallel the Speakon connectors to provide 24v to the controller/motor. Therefore, no changes to the internals of the ammo box, nor any changes to the charging setup are required.
Pictures below.View attachment 3