DenCo™ - Can you believe it?

The AD6DM Power Case was inspired by Julian OH8STN‘s build of his Solar Power Generator. It was AD6DM’s first attempt at putting together a ham radio battery power source from component parts.

It starts off with the vaunted Headway 40152S 15Ah cells. These are similar to 38120 Headway cells that have 8Ah capacity, but are a bit longer and nearly double the capacity.

The BMS is an unnamed 100A BMS, probably very similar in design to the HX-4S-F100A, so those specs will be displayed below.

This power case is useful for plugging in inverters and serves as a backup power source for field radio operation.

General Specs:
Created: April 10, 2019.
Cells: Headway 40152S 15Ah 3.2V LiFePO4.
BMS: HX-4S-F100A -like BMS.
Configuration: 4S1P.
Total Capacity: 15Ah
Current Owner: AD6DM Dennis.

Cell Specs:
Nominal capacity: 15Ah
Charging voltage: 3.65V
Nominal voltage: 3.2V
Cut-off discharge voltage: 2.0V
Charging method: CC/CV
Maximum continuous discharge current: 150A (10C)
Maximum continuous charge current: 75A (5C)
Cycle life: 1500 cycles 1C 100% DOD, 2000 cycles 1C 80% DOD
Working temperature: Charge: 10°C to 45°C; Discharge 20°C to 65°C
Energy Density: 105Wh/Kg
Internal impedance: < 8mΩ
Dimensions: 40mm diameter, 140mm length (172mm with tab)
Weight: 386g

BMS Specs:
1. Continuous discharge current: 100A
2. Instantaneous discharge current: 120A
3. Charging Voltage: Iron lithium charger 14.8V (Switching power supply: 15V-16V)
4. Charging Current: 10A(Max)
5. Overcharge detection voltage: 3.75V±0.05V
6. Over charge detection delay time: 1300 ms
7. Over charge release voltage: 3.6V±0.05V
8. Electricity equalization detection voltage: 3.6V±0.05V
9. Electricity equalization release voltage: 3.59V±0.05V
10. Electricity equalization current: 58mA
11. Over discharge detection voltage: 2.1V±0.08V
12. Over discharge detection delay time: 145s
13. Over discharge release voltage: 2.30V±0.1V
14. Over current detection voltage: 200mV
15. Over current detection delay time: 20mS
16. Over current protection current: 120A±10A
17. Over current protection release: Cut off the load
18. Detection condition: Exterior load short circuit
19. Detection delay time: 300us
20. Over current protection: Cut off the load
21. Temperature Protection: Can use an external temperature switch
22. Main circuit conduction resistance ~20mΩ
23. Working current: ~30uA
24. Working Temperature: -20°C to 80°C
25. Size: 70 x 60 x 8.5mm

Additional Components:
Genasun GV-10 Lithium 10.5A 14.2v Solar Controller
DROK digital voltage/amp/capacity meter
Automotive fusebox
2x Powerpole housing
3.1A Dual USB port
Automotive 60A relay for main switch