Crimson Head: Thanks for the encouragement - right now it's a nice looking bike that won't go anywhere! The few miles I got on it before these battery problems cropped up were very nice, though.... I'm trying to not get frustrated - looking over the ES forum I can see that a lot of guys have had problems with new lithium battery packs - especially the Headway packs - I don't think anything major is wrong and eventually the pack will work great.....Nice build mikeross! The Tidal Force is so sweet. Great work on the battery by the way.
Drewdiller: I'm not sure how to count the cells, but the low one is the cell on the top left of the stack of five cells behind the BMS - pretty easy to get at. I finally got the pack up to 40.6V after about a week (exaggeration) of charging, but when the charger is disconnected it only puts a flash on the CA then goes dead again - I'm thinking now another cell is out of whack and this one is virtually impossible to reach without tearing the whole pack apart. This is the one the black balancing wire (number 1?) goes to. I just got an individual cell charger off Ebay and am going to charge up this questionable cell via the balance wire before actually ripping the pack apart. Haven't yet had time to put the meter on the pack to verify, but ya, I'd like to get out and ride this bike some time soon. Fortunately for me my old Giant LaFree SLA is still chugging along, so at least I've got something to ride to work every day....I recently fixed my Headway pack, and I just _happened_ to buy the same replacement Signalab BMS from batteryspace.com.
It was after installing the new BMS and still getting crap mileage from the pack that I opened it a second time and bought a multimeter...
For you, does it happen to be cell #7 in series (it was at 2.4V for me while others were at 3.4V)? After I read the diagram, it occurred to me that the wiring on that cell was a bit out of order, though I can't recall exactly how anymore.
Oh yes, did you have kind of ho-hum performance before you got your pack sorted out? I was under-impressed with the performance so far. It was OK, but on one stretch I had a hard time keeping up with my wife who was riding the LaFree
If you remember anything more about the pack wiring needing a mod, let me know!