Pack Assembly - Step 2
After setting, for about 1 month, I sorted cells by retained voltage.
4.25V preliminary charge.
(These cells were re-re-cycled from my 2008 builds, plus a few "left-overs")
4.23V+ = 52 cells
4.22V = 80 cells
4.21V = 52 cells
4.20V = 44 cells
4.15-4.19V = ~120 cells
4.10 -4.14 = ~20
sub 4.10 = 12 cells
(All cells are tandem.)
I felt it to be pre-ordained that I should build my prototype 22.2V pack using the 96 cells available from the 4.20V and 4.21V piles.
6s 16P x 2600mAh cells = 41.6Ah.
And ... they fit snugly in the oem eZip RMB battery case!(OEM = 24V 10Ah ... 6Ah usable)
Pack was constructed in 2 - 6s 8p modules.
Center screw post could be retained, but I previously removed it.
So I spaced the 2 modules with 1/4" paneling.
Cells were connected using the oem tabs, on the tandemed pairs.
I used 22ga tinned copper braid as balance connection wires.
The "power rails" were built using 10+ga tinned copper braid, ~40-50A capable.
10ga insulated copper wire used to connect the rails to the terminals.
Charging port 22ga wires replaced with 14ga insulated.
(25.9V 10A charger replaced with 22.2V 12A charger - MeanWell Mods
It should be noted that I performed no capacity test on the implemented cells.
I am testing a theory that retainable voltage is a good indication of condition-capacity.
Also, although I added balance wires, I have not, yet, added a balance plug.
I am planning on using a ethernet plug to attach to ethernet cable to balance charger or VMA (Voltage Monitor Alarm).
Should work nicely with 6s and 7s builds.
Ethernet plug could be safely covered with tape, when not in use?
Ooh! Ethernet covers -