SAFE BATTERY TIPS
- 1. At all times wear insulation gloves.
- 2. Disconnect battery pack from electronics, both negative and positive leads when "off", or serviced.
- 3. Never disconnect under load.
- 4. Use Anderson connectors or breakers for connecting battery pack to electronics.
- 5. Consider charging units with handshaking for off grid and on grid charging.
- 6. Use cutout switch on circuits to prevent runaway.
- 7. Shield ALL exposed electronics from accidental touching with boxes or covers or clear plastic, or rubber, or tape.
- 8. Have "pull fuse" or master breaker within easy reach at source and at destination, marked for emergency personnel, and easy to operate.
- 9. No batteries or fumes near flames, ignighters, fuel storage, components, direct sun, or extreme heat.
- 10. No batteries near fumes or fumes near occupants or other fuels.
- 11. Brake logic, no braking while current is active in capacitors or motor.
- 12. Cut off switches on component doors, and at meter. Consider more.
- 13. Control wires & electronics must be on separate side to that of power cables to prevent RF interference.
- 14. No positive and negative loops.
- 15. Temperature measurements on motor and batteries.
- 16. RPM readings from motor.
- 17. Separate battery packs for emergency lights, maintenance, keeping electronics alive.
- 18. E-meter, Zantex gives state of charge, amperes used, etc.
- 19. When fast charging battery pack, may need air or water cooling.
- 20. Have AC inverter to run water pumps and auxiliary items.
- 21. Maintain lubrication. Prevents locking up of gears.
- 22. Do not over spin motor or spin motor without load.
- 23. Forced motor cooling at low speed and current anticipation.
- 24. For first time installation, use limited power.
- 25. Maintain battery management system.
- 26. Torque stabilization for motors need support attachment on front and rear to prevent short life or handle excess loads.
- 27. Motor gear attachment use taper lock with compression screws.
- 28. Frame and tower construction use chrome alloy 4130 aircraft quality, lots of bracing, tig weld, and pre-heat.
- 29. Design "Lift Point" on frames to remove large or heavy components.
- 30. Determine center of gravity (use 1.4 to 1 hypotenuse line).
- 31. Unitec welder three phase for welding battery tabs.
- 1. Crimp connectors are much better than solder.
- 2. Use Teflon wires for all electronic connections and battery pack connections.
- 3. Consider special crimper (expensive) or AMP aircraft crimpier (or weld a 13mm hex socket & cable cutter).
- 4. Use thick walled connectors. No separate or split type (braised OK). Consider Zeus fasteners.
- 5. Perform a "Tug Test" at 70 percent on connections.
- 6. Use DEM nuts for sheet metal.
- 1. Use optical isolated commutation.
- 2. Do not use carbon fiber to house battery pack (unsafe).
- 3. Glue batteries to circuit board with aircraft tank glue. Try Sinco Sealant gun.
- 4. All wiring must be twisted to prevent RF interference.
- 5. Rubber cap all of the exposed connections.
- 6. Require fuses on chargers and destination.
- 7. Require excess full charge connectors.
- 8. Parking brake must LOCK with kickstand on bikes.
- 9. Consider backup contact switches. The extra protects in case of failure.
Thanks to Bill Dube’, Ken Koch, Lee Hart, John Wood, Roland Wiench, Wayne Alexander, Roger Stockton, Victor Tikhonov, Chip Gribben, David Roden, NEDRA, Roderick Wilde, Wayland, Steven Ciciora, Derek Barger, Scot Colburn, Rich Rudman, Jim Husted, Electric Louie, James F. Jarrett, Jay, Robert, Randy, Uve, Father Time, Don, Otmar, pioneers, racers, and Electric List members for training, guidelines, safety tips, and procedures.