replacing lead acid with lithium battery

[billyboya]

I have a new lithium battery arrived today, it fits on its side in battery case so all ok. but now i need to know, about wiring it all up. I will need to fit the charger plug tight in hole as its slightly narrower. But I believe the 2 other wires IE: discharge red and black goes to discharge pins in picture Red to positive + pin and black to negative - pin
but how do i wire up the 2 fuse wires in picture

I assume the battery needs a full charge as red light is on the charger. and its been on 1 hour so far so imagine it does

 

[Deleted member 4366]

That's very easy. You don't really need a fuse because the battery has its own protection (BMS). Without the fuse, cut the red wire off the red connector and join it to the terminal marked plus, then cut the black off and join it to the minus. Do not cut them together, or any way allow them to touch.

To do it properly you should solder a ring terminal to the wire, but It will probably be OK if your wind a turn round the terminal and tighten the nut. I'd use a couple of washers to get a good grip on the wire.

If you want to use the fuse, you should join one wire to the positive terminal, like it was before, and the other wire to the red battery wire.

For the charge lead, drill the hole to the size of the connector and glue it in place with some epoxy or silicone, or poke it right through and leave it hanging, then seal the hole with silicone.

Stuff some polystyrene or foam around the battery to stop it moving.

 

[billyboya]

That's very easy. You don't really need a fuse because the battery has its own protection (BMS). Without the fuse, cut the red wire off the red connector and join it to the terminal marked plus, then cut the black off and join it to the minus. Do not cut them together, or any way allow them to touch.

To do it properly you should solder a ring terminal to the wire, but It will probably be OK if your wind a turn round the terminal and tighten the nut. I'd use a couple of washers to get a good grip on the wire.

If you want to use the fuse, you should join one wire to the positive terminal, like it was before, and the other wire to the red battery wire.

For the charge lead, drill the hole to the size of the connector and glue it in place with some epoxy or silicone, or poke it right through and leave it hanging, then seal the hole with silicone.

Stuff some polystyrene or foam around the battery to stop it moving.

Thanks for your help d8veh so i was right about discharge wires then.

you say if i want to use my fuse I join 1 wire to discharge positive terminal, and you also say other fuse wire to red battery wire but there is only 1 red wire from battery which is going to positive discharge terminal. so isn't that meaning both wires on fuse going to same terminal positive discharge

also how long would it take to charge this new battery as its been on charge 3 hours and charger light is still red. or is new battery completely low and needs a full charge before use

regarding battery I have placed some thick pieces of rubber each side and will also pack some in front too

The battery charger green light just came on after 3 hours so thats good. I just took bike out for a test run approx 2 miles and its great. all working fine and also its going a extra 5 MPH speed as before I got approx 15 MPH now its 20 MPH so happy about that. probably due to battery being much lighter. it was a joy to ride bike. regarding that battery charger terminal d8veh it will fit inside hole but just need some poxy as you said. or maybe can see if a nut will fit to tighten it up

 

[Deleted member 4366]

The fuse has two red wires. One goes to the positive terminal where you have your red battery wire (take the red battery one off). Join the other to the red battery wire. By join, I mean solder.

The charge time is correct. The battery would be half-charged when it arrives, and it should take about 5 hours from empty.

I'm glad you like it. Definitely a worthwhile and not too expensive modification. It should last at least a couple of years - maybe four.

 

[billyboya]

The fuse has two red wires. One goes to the positive terminal where you have your red battery wire (take the red battery one off). Join the other to the red battery wire. By join, I mean solder.

The charge time is correct. The battery would be half-charged when it arrives, and it should take about 5 hours from empty.

I'm glad you like it. Definitely a worthwhile and not too expensive modification. It should last at least a couple of years - maybe four.

Oh I'm with you now one wire from fuse goes to positive discharge terminal and the red wire from battery goes to other fuse wire. So basically it's like a in line fuse between red battery wire and fuse

Yes very pleased with bike now as it has increased speed another 5mph. Plus lot lighter battery. I still have to fit charge terminal tighter as it fits hole fine but slightly smaller so just needs like u said poxy round it. I was a bit worried when I first tried lid of battery cover as it was higher and wouldn't close. Then it checked again and noticed some thin plastic under lid in middle but was fine once I removed it

I do apologies if I have been a pain. But do appreciate all your help and others you all have been fantastic. I know I am stuck now with 2 old lead acid batteries. And someone did suggest using them on bike. As a back up range. But I won't have a clue about wiring it all up plus didn't want to take bike apart again to fit it. I would have to carry both batteries in panniers which would be awkward as I use them for shopping. It does sound a good plan to save batteries but I'm no good at doing all that. Unless I get pictures showing how to

 

[D8ve]

Billy I told you D8veh knows his stuff.
I have one spare lead acid battery unused in the garage.
Perhaps you can put them down to learning.
I'm happy it works give us a review when it's been going a while..

 

[billyboya]

Billy I told you D8veh knows his stuff.
I have one spare lead acid battery unused in the garage.
Perhaps you can put them down to learning.
I'm happy it works give us a review when it's been going a while..

Yes all seems ok I just have to wire up fuse and make charge plug secure with poxy glue. But I am a bit worried about the battery now as last night it was fully charged after 1 hour after riding approx 2 miles. but later last night I decided to test battery again on a charge, but light was just flashing green, so I assumed its because it cant take anymore charge. anyway I try again this morning and now light has been on solid red for 1 hour yet last night it was flashing green. but bike has not been out at all. so is it normal for battery then to drain when not being used.

This is not making any sense at all as I turned off charger after 1 hour it was still on solid red, when i turned it back on again its flashing green again. is this charger faulty or something as last night after charging up battery which took about 1 hour it was solid green and bike hasd not been used since last night

Another problem I wired up the fuse 1 red wire to red wire on battery. other fuse wire to positive discharge connection. the fuse is a 5A but just tried bike got a few yards and fuse keeps blowing tried 2 times now same thing so i am disconnecting the fuse and putting it back to how it was as like you said d8veh the battery has its own fuse BMS

 

[Deleted member 4366]

The fuse should be at least 20 anps. I'd use a 25A one. The 5Ais for the charger. It's optional whether you put one on the charger, which has probably already got one in it anyway.

The charger flashing green can mean anything. Every charger is different. It won't blow up your battery because the battery has a protection system in it, which prevents over-charging or over-discharging.