Im writing between your lines....
Doctorbass wrote:
The air spray is a nice idea to remove lead!!.. Normally we use vaccum.. and you use pressure.. I love that :wink:
But at first I clean the brass bolts(8mm) with the angle grinder, at 2nd I used "WD40"-spray and then I can remove the remains of soldering with compressed air!
The way i used before to remove lead is to suddenly hit the desk edge with the cell to make the liquid lead to drop... i know air pressure is better.
It's more to get the dissolved soldering remains away.
I love the big blinding flash in the welding part fo the video.. !.. I see multi kW blast!!
At first I'd tested the battery with 3 serial H4 auto-bulbs, so I can calculate exact the power and of course the time.
I'd connected it to high beam, here we have 60W on the H4. That makes 3x60W=180W. The batt has got 1000Wh, so it takes normally 5.5hours to take the batteries power. But there's still 34Volts... 
Recharging, then I tested it with more H4 bulbs..... there's really no load!!! Then I decided to take the welding electrode.... POOOFFF!!!
The balancer are simple and i never saw them on the internet... we usually use the Tppacks bms here for all the job.
It's from a german electronic store: http://www.elv.de/output/controller.aspx?cid=74&detail=10&detail2=13693&flv=1&bereich=&marke=
btw.. The LVC might be the weak part of your desing since it dont monitor individual cells voltage and just monitor the pack voltage.
I want to see the voltage of every cell at first, but I don't need it really. My decision, it's only a bicycle and not a F-16 jet fighter, I only need the overview!!! So I can see only the pack voltage in the cockpit.
I think your charger desing is very simple and basic.... but tit is not CC-CV and might prolong the charging time. I mean a less powerfull charger
WITH CC-CV should decrease the charging time. A simple toroidal with rectifier will charge but since it is not regulated the current will decrease as the pack voltage increase and charging time will increase too.
I'd tested so much electronic chargers and 2 chargers are burned down. I must build on my charger all time! I decided to created my own charger, without electronics... processors... microcontrollers... Only a 230V plug and a 43V plug, ready!!
Why do you build a so nice and powerfull pack and just charge it with a too basic charger desing? to me it's a big risk to damage the pack. I already thought about that with toroidal too and it was discussed alot on E-S and it finally ended by explaining why it can be risky: the AC is a very unstable source.. the most stable parameter is frequency( depending on teh country you are...) and teh voltage can vary up to 8-10%.. and a lipo pack can not endure that. Also the measured RMS AC voltage is not constant because it might also have some HF spike or parasitic that your multimeter will not see but that might boost a bit the output voltage for few volts with few mA current so it could overvolt the pack... its, not a 100% fact but i already saw it happening
The AC is really exact here! I cannot overvolt the pack, because every balancer can handle about 25Watt and there are 20pieces. So in every recouperation brake I get in a short time high AMPs into the pack, that's a higher critical factor. "NORMALLY" I don't need a charger, it's only for an emergency situation!!!
I think your capacitors are not necessary since it's just for charging.. so it's like charging with pulsated DC to 120Hz.. and should be ok without caps.
Every charger has got into the ending a cap to smooth the residual ripple.
You work with EV parts like no one do and it's what make it impressive.
I'm working out a new system..... :lol: :lol: :lol:
Your video are awsome and you do great work.. thanks for sharing!
Thank you and of course thanks to endless-sphere (Homepage,servers etc...)
Doc
Lowracer
Nice!
..now, that is a SERIOUS soldering iron ! 
