Zippy Flightmax / Turnigy lipo testing

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I got this from misconnecting a single 6s-5000 pack, in a way it shorted and melted the 4mm bullets.


View attachment KFF-01.jpg

This was nothing, compared to 24s, but quite a spectacular show, nonetheless. :roll: The worst part was that molten copper, from the bullets, ended up down between my legs, narrowingly missing Big Jim and the Twins, but burning through four layers of skin on my upper inside thigh. :shock: :oops: This happened two months ago, and it still hasn't healed completely. An inch to the right, and it would have been KFD. :mrgreen:

-- Gary
 
Best regards to you all and I hope every one of you will get well with yours injures for trying to make ebikes more awesome then they already are. :D
 
KFD = brutal
 
out of commission for more than 2 months :shock: :shock:
 
Some nice little burns there fellas, I still think I have you all beat with my welding burn :p

Hope you all heal quickly ESPECIALLY GGoodrum so he can get themz kits done :: wink :: LoL ...

KiM
 
AussieJester said:
Some nice little burns there fellas, I still think I have you all beat with my welding burn :p

Hope you all heal quickly ESPECIALLY GGoodrum so he can get themz kits done :: wink :: LoL ...

KiM
Click to expand...


Holy ouch KiM! You're damn lucky you didn't have to walk on that! ;)
 
What a strange thread. Gary please don't show us your crotch burn. :shock:

This thread is soo tangental, it's classic. Starts out with zippy lipo testing, goes into bms for days, every now and then somebody asks Gary if this charger will work in this configuration, and now we are on flesh burns. What could be next? Oh yeah, someones garage burning down. :wink:

Carry on
 
KFD, ouch! :shock:

liveforphysics said:
Holy ouch KiM! You're damn lucky you didn't have to walk on that! ;)
Click to expand...
Oh smooth man, real smooth. haha
 
etard said:
What a strange thread. Gary please don't show us your crotch burn. :shock:

This thread is soo tangental, it's classic. Starts out with zippy lipo testing, goes into bms for days, every now and then somebody asks Gary if this charger will work in this configuration, and now we are on flesh burns. What could be next? Oh yeah, someones garage burning down. :wink:

Carry on
Click to expand...


You can blame me for that....
I am as tangential as they come.
Bad habit!

There is some reason for the tangential though - to make glaringly clear how dangerous this stuff is.
Now people are coming along, seeing this thread, ordering up a box full of these lipo, then making KFC (and sometimes KFD).
It is important to remind people that these lipo packs are not like a string of NiCd's...

To answer the question a page back - I would not consider lipos fully charged that are less than 4.10V
I prefer 4.15 at a minimum - but we are talking only a few percent.

-methods
 
I charged my pack to only around 4.1v / cell the other week and got about 9.2ah from it (2P obviously). Mind you it was only one weak cell that hit 3.1v, all the others were still at 3.5 at that time. They probably weren't far behind though. Charging to 4.18v I get 9.6-9.8 ah.
I rarely take it that far though. I charge my packs twice daily and usually only pull 6-7ah from them. It only on the occasional weekend ride when I go off into the bush for an hour or 2 that I use max capacity
 
Soldering stuff from underneath I put my weight on my hand to get up but placed my hand ontop of the 40watt soldering iron. Burnt a rather large hole in my hand. Third degree.

I hate pain.
 
I knocked my soldering iron off the bench once and instinctively grabbed it as it fell towards the floor. That's a mistake you only make once.
 
317537 said:
Soldering stuff from underneath I put my weight on my hand to get up but placed my hand ontop of the 40watt soldering iron. Burnt a rather large hole in my hand. Third degree.

I hate pain.
Click to expand...

FUCKIN' OUCH!!! I was welding a few hundred fittings on a jig one time, finished the last one took of the gloves sat back looked over the pile i had just completed before pulling the last piece from the jig, you just cant let go of this hot stuff quick enough before it burns the utter shit out of you, can just imagine having your full weight on the soldering iron Leslie, would have been quite comical as an observer watching you trying to get off the soldering iron, the frock this hurts "dance" after the incident would of also been worth a look too hehehe soz man i feel your pain i burnt myself more times than i care to remember ;-P

KiM

p.s HAHAHA hyena i bet you would do it again, only need to be distracted thinking about what your doing or a lil tired and instincts kick in CURSE those instincts
 
Several years back. I was re-soldering an AC lead to a power board for some project. I had neglected to unplug the board from the power bar. I had my face close down to the board, and the lead popped up and touched the tip of my nose. I got a real nice jolt. No damage.

The most memorable shock though, was when I was 10 or so. I had just got out of the bath and into my pajamas & was still wet. I went to help my Dad in finishing the basement. He asked me to change a burned out light bulb. Bam! I got nailed. No damage other than a broken bulb, but I'll never forget the feeling.

Thanks for sharing your electrical adventures guy's. Your cautionary tales are being taken seriously.
 
AussieJester said:
HAHAHA hyena i bet you would do it again, only need to be distracted thinking about what your doing or a lil tired and instincts kick in CURSE those instincts
Click to expand...

Yeah ok, so I did do it a second time :p but it was only for a split second and somehow I managed to touch it and let go before getting a serious burn. The 3rd time I did it memory overruled instinct and the iron hit the deck and broke. $10 happily spent after a bad burn though. I now have a power board connected above my bench so if I drop it now it doesn't hit the ground because the cord isn't long enough. Yeah, now it just swings and burns my legs instead :lol:
Geez I sound like a clumsy oaf don't I, I really need to de-clutter my workspace so I'm not forever knocking stuff over!

Did someone mention this thread has gone off topic ?
 
OT maybe, but relevant and informative, I think. :roll: :)

One other recommendation is to not wear any jewelery, while working with these things. A while ago I shorted a couple of a123 cells, when a 10-cell pack I had just removed from a Dewalt case, slipped off a workbench and I caught them in my hand. I ended up arc-welding a ring:

a123-M1-burn.jpg


Okay, back to the balancers...
 
UPDATE I'm getting closer to releasing the balancers and the 12s package deals, which inncludes everything needed to build 12s3/ or 12s4p packs, even down to the shrink wrap. The reason for the delay is that I had an issue with the green LED not going off when the HVC cutoff trips (LED should be fully red. Richard helped me fix it, which required adding a resistor. Anyway, I ordered new boards this morning. Here's what the layout for the 12s version looks like:

View attachment 12-Cell Charge Balancer-v3.5.png.png


It is sized to fit into a 3x4x1 extruded aluminum box. I'm also doing a replacement lid for this enclosure which already has holes for the LEDs to pop through, plus connections for a Wattsup meter, an 18-pin AMP 4.2mm PE Series connector and also has the HVC cutoff circuit. Here's what it looks like:

View attachment 12-Cell HVC Cutoff-Lid-v3.5.png


The HVC cutoff parts are mounted on the bottom of the lid. The Wattsup will go between the two rows of LEDs. The supply connects in at the bottom, and the pack connects through a single 18-pin plug that matches up with the connector on the lid. I also had some small adapter PCBs made for connecting the balance plugs from two LVC/Parallel Adapter boards, and a set of charge leads:

View attachment 12s Adapter-01.jpg


In addition to providing a single charge and balance connection, for a 12s pack, this also saves wear and tear on the JST-XH balance connectors, which tend to get a bit loose when plugged and unplugged frequently.

The last piece of the "puzzle" is the new combo LVC and parallel adapter board I just finished doing. The previous version had LVC circuits and connections for paralleling up to four 6s-5000 pack balancer plugs. This new version now adds 4mm bullet plugs so that the main pack leads can also be paralleled on the same board. Here is what it looks like:

View attachment 6s4p LVC-Parallel Adapter-02.jpg


The new LVC/6s4p Parallel Adapter is available now, either as a kit, or fully assembled and tested. The balancers will also be offered in kit form and fully assembled. In addition, I will offer a board-only option, with a Mouser/Digikey BOM, like we do with the v2.6 BMS board.

Anyway, I'm getting the new boards by Friday, so I will hopefully wiill be able to make everything available, including complete 12s pack making kits, by this coming weekend.

-- Gary
 
OMG Gary! That is so nice! You better watch out making stuff like this, people aren't going to be able to burn there garages and homes down if you make LiPo so darn safe and fool-proof. :)
 
Wooohooo !!! :shock: :D Yeah !

This is perfect ! my 10ah PSI pack is ok for testing but not giving me the range i want, 20ah worth of lipo should be just about right however ! I'm itching to buy some lipo's right now but Winter is very near out here ( -3 celcius this morning, one COLD ebike ride to work ! ) snow won't be far behind.. Best to wait until it all ends and get a fresh pack for next season..

Are you planning to have these available down the road ? or is this a limited time offer ?
 
johnrobholmes said:
Could this be adapted for 6s liFe packs easily?
Click to expand...

If you mean the LVC/Parallel Adapter then yes, simply by using the 2.1V version of the TC54 detectors. The balancers will also be able to be used with LiFePO4 cells, with a couple of resistor changes, but I haven't worked out the values just yet. With the current values, the LED is orange until the shunt starts to come on, and then it transitions to green, when the shunt is fully on, which happens at 4.15V. If the voltage hits about 4.25V, the LED turns red and the HVC opto trips, which causes the charge current to be cutoff. It stays that way until the shunt pulls the voltage down below around 4.21-4.22V. Anyway, for LiFePO4, the shunt turn-on point needs to be set to about 3.65V, and the HVC set point should be around 3.75-3.80V.

-- Gary
 
liveforphysics said:
OMG Gary! That is so nice! You better watch out making stuff like this, people aren't going to be able to burn there garages and homes down if you make LiPo so darn safe and fool-proof. :)
Click to expand...

Ha! :lol: At the risk of Methy calling me "Captain Safety" again, I would like to make this as foolproof as possible. This is something I need, as much as anybody else. :roll:
 
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