DIAGNOSIS OF PING 60 VOLT 30 AH LITHIUM BATTERY PACK

[chuckufarley]

The pack will not charge .......this is the video I will send to ping battery so that they can decide if the battery has a problem or just the charger ..... I believe it is the charger....

http://contour.com/stories/diagnosis-of-60-volt-30-ah-lithium-battery-pack

 

[dogman dan]

Well, you will just have to type something. Whatever you are saying in the video, I can't hear it.

The red light is showing on the charger, so that rules out the single most common problem, a broken plug on the output side.
Looks like the charger is trying to charge.

 

[dnmun]

post up a picture of what you are doing, with all the wires and connections visible to examine, and measure the voltage on the output of your charger. are any of the leds lit now?

 

[darkshirikens]

That is very puzzling especially since you can see all the cell connections does that charger have a voltage switch that switches from 120v to 220v cause it mint not be in the correct position i dont know if a continuity test would be valid in this situation but might be worth a try just to rule out a connection problem. Good luck!

 

[999zip999]

My guess is the wires to the xlr plug. How about the fuse ?

 

[dnmun]

i could not watch that video, got so creepy right from the start. but if there is some way to convince him to just measure the output of the charger, that would help.

 

[dogman dan]

Just watched the start of it again, on a computer I could turn up enough to hear it.

I thought it looked like the red light was on. He says it's not. Broken plug, or even possibly disconnected inside the charger.

Most common fault known to battery charging. He doesn't have dead cells, nor is it so discharged that the charger won't start. He's got about 3.2v per cell on all of em.

It's the plug or some other disconnect on the charger output.

 

[chuckufarley]

The charger is definitely the problem... My client MARRS and Li Ping have decided to make it a 48v battery pack because this is the second charger that has died for this battery. There is an inductor in the charger next to the relay that activates the charge output wires (inside the charger) that looks physically burned....also there is charge voltage (80v) before the relay ....the charger is making voltage but the relay to send it to the battery is not tripping .....at first I thought is was a cell imbalance issue ...but its too expensive of a battery to try bypassing the relay.....I'm just going to make the repairs I am asked to make and save the learning process for my own stuff....The battery will be downsized to 48v.

If anyone in the US has a signallab V.2.5 BMS and 48v charger handy that they want to sell ....I may need this bike to work this week and not wait for ping to send it to me PM me or call me (714)381-7761 im in Orange, CA. USA. I would also be interested in buying a working 60v charger if i could get one here this week.

 

[dnmun]

can you take a picture of the inside of the charger, and close enuff we can see the components in the back end where you said there is a relay?

 

[chuckufarley]

Here is 2 pics the relay looks and tests fine..... but the blue inductor next to the relay has some brown discolorations on the side of it so I am assuming it is burned. I will probably make another posting later where I attempt to repair this unit...The priority here is getting the battery functional again immediately.

And in reguards to my earlier request in my posting for parts ......I will be interested in good sources for parts so feel free to contact me anytime. But we're going to wait for Ping for the parts ....Thanks anyway..

 

[dnmun]

never seen this charger before. when did ping start selling this?

so when the relay clicks on the green led turns off and when the relay turns off the green led turns on? is it possible the pack has to be plugged in first for the relay to activate the output? i doubt if that toroid overheated from excess current if that is what you meant. but i'm not there either.

if you have 80V then i thought maybe those caps woulda baked but doesn't look like it. so they must be 100V caps.

 

[chuckufarley]

yes they are 100 volt caps but there is another circuit that activates the relay I don't think the caps are bad at all. I did try it with the battery pack hooked up in the beginning of the video you can see me turn it off I will attempt to fix the charger but I need a schematic for it. there is a circuit that activates the relay under the correct voltage conditions but the battery is not so discharge that it shouldn't work but I can't figure out what is wrong in less I know what those conditions are I think I will asking for a schematic for the charger and bms. I have tried all the normal testing procedures there are no missed connections or wrong connections at all I did go to UTI.....I am an automotive technician by trade

 

[dnmun]

man, it would take some smarts to figure it out. no way to even know where the traces run on the board to see what is going on with the relay, but it is obvious the relay is on the output and if you have 80V to one side of it that most probably is the problem. all new to me.

 

[chuckufarley]

the only thing I would be able to do is isolate and test the individual components maybe I get lucky but it is a valuable charger and would be worth fixing I'm gonna screw that when I have more time

 

[999zip999]

What motor and contoller have you been running and at what amps for how long, do you have C.A on your project ? Or is this a brand new pack just being charged ?

 

[dogman dan]

So if I understand right, this charger is different from the 48v version?

You never told us, of course, till now, about the first burnt charger or that this one had toasty parts inside. So our guesses that it was the plug were right on for the info we had.

 

[999zip999]

I'm getting at has the battery worked.

 

[chuckufarley]

yes the battery has and does work....he just needs a new 60v charger....the boss seems happy at 48 volts. he has less problems with lower voltage and he wants his bike to be user friendly. it's a cruiser....li ping seems to be in agreement since he is sending instructions and a 48 volt bms and charger I'm just a tech.

 

[Jason27]

What's with all the problems with ping packs lately? Geez every week its someone else have issues..

 

[dogman dan]

Ping is still stuck with typical QC for the bms and chargers, no matter how good the cells are.

You know how it is, once in a while the factory sends out an entire pallet marked checked while the checker was off doing a moonlighting job, or sleeping because he worked the second job all night.

Then that same stuff ends up in chargers, bms, tv's, you name it. Works for a day, then poof.

 

[chuckufarley]

That is true sometimes when things are mass produced bad stuff gets through, I make tons of money buying repairing and reselling consumer electronics. ...But Ping is completely willing to do whatever it takes to make it right .....That is why we use them ....I want to go higher output ....like Headways or something but MARRS seeks a good balance between reliability and power since he makes a "production" vehicle. :|

 

[dnmun]

i haven't seen anything in this thread that implies and certainly does not support the idea that this battery is defective in any way. like i said the video was too creepy to watch, so i am limited because that is all the info, but all i have gotten out of this is that the charger does not charge the battery.

to just make blanket statements about how there is no quality control or there are lazy inattentive people assembling the packs for ping is not supported by anything in this thread.

all we know is this guy cannot get the charger to charge, i still do not know if it really is a ping charger, it just does not look like any ping charger i have opened up.

why do people always start trashing ping, when he has years of experience and reliable service, and then someone who has never worked on a battery before has problems decides that it is bad or poor quality control because it doesn't work for him is really irritating. i tried to help, but there is nothing to work with.

 

[chuckufarley]

sorry you miss understand me I was not trashing on ping ......their batteries and customer service have been outstanding. we did have a problem ....with the charger and the configuration of the battery. I was diagnosing the problem myself ... thanks for your help

 

[chuckufarley]

I'm gonna do a thread about the charger I have time to look at it

 

[chuckufarley]

Sorry missed a few peoples questions.....The video was literally sent to PING... I wanted them to see that I had tested it right.....So they would not waste time questioning my methodology and actually help .....which they of course did..... And hey buddy you know whats creepy....You wasting time commenting on what u dun unustand. Everyone else ...Thanks I'll try to be more concise.