Reversed cell replacement.

[Ypedal]

If it's a High-Power brand charger.. it does trickle.. the bulk charge goes on until temp-cut-off.. then once the light goes green it goes to trickle.. so leave it on green for a few hours at lest.

Could be a bad interconect or battery tab causing resistance.. go for a hard ride then feel the pack for a hot-spot maybe..

I like the needle idea... thanks. !

 

[knoxie]

Hi

Yes thanks for the tips i will do that as you may be right about that I will check for hot spots on the packs, the needle idea is great and keep the pack nice, ok if you have to break a pack you have to but my packs are in 12V blocks so I f I can isolate which block it is in I can keep them neat and tidy, it should be quite obvious feeling around under even 5A of load if there are any bad interconnects.

Thanks for the tip, I may post some pictures later

Cheers

Knoxie

 

[knoxie]

Right

Loaded up the other pack and tested it (see pictures) but it seems ok? will test it on the bike again, still its a good way to test the pack without stripping it down, will check for hot spots on the welds whilst running the pack next.

Here are the pictures of how I tested them, just pushed 2 x needles in to golf tees and then wrapped signal wire around them, I have done this before to check continuity in wiring where I couldn't get to an exposed end, works very well.

Cheers

Knoxie

 

[Ypedal]

Ok.. so this project is still on -going..... yesterday i did the invetivable.. have been avoiding this for quite some time now.. but it was gonna get done sooner or later.....

I SOLDERED the tabs to the cells... ( will have pictures later )

Re-packaged the pack with thread tape, created a venting system.. and built a cardboard template for the lexan sheet...

I need to figure out a wiring path, and re-solder a fuse holder in there.. ( was only using 1 fuse for 2 packs before.... )

Pictures later..

 

[Ypedal]

So the fun continues.

I soldered the tabs onto the batteries, i've been wanting to do this for a while now, but had not worked up the nerver to actually get it done...

But..

Voila !

Tabs soldered, Thermistor hot-glued securely..

 

[Ypedal]

This is the original adhesive cardboard cover i removed to repair the bad cell.. i cut this in 2 and put it to good use.

 

[Ypedal]

Got the prototype box tonight..

I like it so far !!