PINNED - Lithium battery conversion/info

[fishinjunky]

In conclusion it's the alligator clips not giving a good enough connection

Hope you didn't clip on the stud. It's high resistance then, and high heat.

I stopped using them. I'm going to use ring terminals from now on.
I think I'm going to have to cut a notch out of my battery box to get a few mm for the 2 cells going long ways. The 6 in a row will fit but the other 2 are slightly to long.

Any tips on how to seal my battery box after I cut a notch, maybe sheet of thermo plastic sheet? Reinforced black tape?

Here's a pic so you can see the 2 cells that are longways I only need to cut a 54mm wide notch to accommodate the length of the one cell

[fishinjunky]

I've come to far and spent to much $ to give up now. My main concern is fitting the pack in my battery box I may need to cut a 54mm wide cut out in the back of battery box to accommodate the couple mm the cell going longways sticks out

But I could use some ideas on sealing the battery box after cutting the 54mm wide piece?

[foghornleghorn]

Why are you not building a rectangle with a hole in the centre?

Would reduce the length. See image.

[fishinjunky]

Why are you not building a rectangle with a hole in the centre?

Would reduce the length. See image.

wynh5lah.jpg

Thanks that would give me just enough to fit right now I'm at 13.7" and I need to be at 13.1"

Looks like I'll be untapping an taping again

[Burgerman]

2 steps forwards and one step back. Rinse and repeat.

[fishinjunky]

2 steps forwards and one step back. Rinse and repeat.

for sure.
this time ill remove the lead batteries and test fit the cells in the battery box before putting the pack back together

[fishinjunky]

Just took out the super heavy lead bricks an test fitted the cells :din the battery box an they fit perfectly I'm so HAPPY!!!

[Burgerman]

What chair again?
And I forgot which cells... Do you have a link?

[fishinjunky]

What chair again?
And I forgot which cells... Do you have a link?

It's a bounder 300m one year old with the 4 torque motors group 24 batteries

Cells are 8x202ah I got them from the person expresso recently ordered from. She was easy to work with an keeps in contact to see how the progress is going.
IR is 0.3
annette_ou@yabohybridbattery.com

[fishinjunky]

Got the 8 x 200ah pack put back together

[fishinjunky]

I got one of those cell monitors with a low voltage alarm. What should I set it for?

[shirley_hkg]

LiFe or 3.00V

[Burgerman]

But be aware that it likely runs on any cell count from 2 to 8. And so RUNS from cell 1. And if left connected all day or in storage unbalances the pack.

[fishinjunky]

But be aware that it likely runs on any cell count from 2 to 8. And so RUNS from cell 1. And if left connected all day or in storage unbalances the pack.

Oh ok I see, in that case I'll just use it to spot check.
Once I get back out I'm going to take note of all mileage with the speed terrain hills etc. and note the amount of AH used to get an idea of range.

[fishinjunky]

I finished capacity testing cell #1. I charged to 3.6v then discharged to 2.9v an pulled out 190ah the cells are advertised as 200ah, is that good or bad?

[Burgerman]

Thats exactly what you would expect. They gain a little in regular use, and you left a little in them so you dont go down to 2.5v which isnt a great idea.

[Burgerman]

Thats exactly what you would expect. They gain a little in regular use, and you left a little in them so you dont go down to 2.5v which isnt a great idea.

[fishinjunky]

will i need to change any of these battery settings in my chairs programming?
i have linx

[steves1977uk]

I wouldn't bother even trying to change those. On R-Net I left them as stock as you can't set the Low Cut-off voltage to 24v, doubt you can on LiNX either as they assume we all use Lead bricks!

Steve

[fishinjunky]

I wouldn't bother even trying to change those. On R-Net I left them as stock as you can't set the Low Cut-off voltage to 24v, doubt you can on LiNX either as they assume we all use Lead bricks!

Steve

thanks
ok ill just leave them as is.

[fishinjunky]

Thats exactly what you would expect. They gain a little in regular use, and you left a little in them so you dont go down to 2.5v which isnt a great idea.

thanks bm.
i feel good about the purchase

what to do with all this range cant wait

[Burgerman]

Its there to allow you to never worry about going to the pub in the evening after a big day out. Its there to totally remove all range anxiety. You dont have to use it all.

Unless you are expresso.

[fishinjunky]

I'm charging each cell individually, I'm charging the first cell, at 15 Amps is shows 3.64v if I increase the amps over 15 amps it makes the voltage spike up to 3.8v. The balance lead shows 3.3v. Does that mean this cell can only take 15 amps?

Here is the specs

[Burgerman]

If I set the PL8 to 3.600V then charge at 40A as soon as it goes over 3.600V it throttles back the amps and the current gradually tails off to almost zero.

I'm charging each cell individually, I'm charging the first cell, at 15 Amps is shows 3.64v if I increase the amps over 15 amps it makes the voltage spike up to 3.8v. The balance lead shows 3.3v. Does that mean this cell can only take 15 amps?

Here is the specs

So what you have written makes no sense to me. The charger is supposed to LIMIT its output to whatever CV voltage you have set. So I have no idea what it is you are reading or looking at. Or if the charger is doing as its supposed to be doing!

If the balance lead shows (read by charger or voltmeter??) then I have no idea why you see more somewhere else? On the charger??? And if thats the case then your charge lead has a bad connection.

[fishinjunky]

If I set the PL8 to 3.600V then charge at 40A as soon as it goes over 3.600V it throttles back the amps and the current gradually tails off to almost zero.

I'm charging each cell individually, I'm charging the first cell, at 15 Amps is shows 3.64v if I increase the amps over 15 amps it makes the voltage spike up to 3.8v. The balance lead shows 3.3v. Does that mean this cell can only take 15 amps?

Here is the specs

So what you have written makes no sense to me. The charger is supposed to LIMIT its output to whatever CV voltage you have set. So I have no idea what it is you are reading or looking at. Or if the charger is doing as its supposed to be doing!

If the balance lead shows (read by charger or voltmeter??) then I have no idea why you see more somewhere else? On the charger??? And if thats the case then your charge lead has a bad connection.

I set voltage to 3.6. I'm reading the voltage from the balance lead at 3.3 on the charger.. The voltage on the charging leads also read 3.3 but when I start the charge the charging leads show 3.8v (if set over 15 amps) . Once the balance lead shows 3.6 the amps drop until it reaches the cut off point I set. Then it stops the charge

I'm reading all voltages from the charger

Could the charging leads be showing the 3.8v because of current going through them. That's only time its different then what the charger show through the balance leads is when current is going through the charging leads

[Burgerman]

They could show a higher voltage flowing from the charger if the cel voltage is correct. The difference is bigger if the cables are making a bad contact or are very thin. To be .2V higher per cell at only 15A is "reasonable". Thats a 3 watt loss in the big charge cable. What does the accurate digital multimeter say that the cell voltage measured at the cell actually is while charging at 15A? 3.600V or less? or More?

If corrct or less thats fine. Its maybe just an odd way to display whats happening on th charger?

Remember that the charger charges for around 95% of the time. And STOPS charging 5% of the time (or even 50% of the time depending on the pulsewidth it is using). And it reads the voltage of the cells during the off time. It does this at high frequency. So its invisible to you. So theres 5 different voltages...
Cell voltage while charging.
Cell voltage while NOT charging during the gaps.
AVERAGED cell voltage.
Charger voltage while charging in the on times.
Charger voltage while charging in the off times.
AVERAGED charge voltage.

Your charger is likely showing you 2 of the above! The reason that there are differences is because of ohms law on the cables, and the cells own resistance. This is how the charger calculates internal resistance. INTERNALLY it knows all 6 of these values.

[LROBBINS]

Are you using a ZXD power supply, and when you say you measure voltage at the charger do you really mean at that power supply? Do be aware that the ZXD monitors current flow and adjusts the voltage at its circuit board so that you actually get the set voltage at the device - it is correcting (or approximately correcting) for voltage drop in the wires. If you have the PL8 connected to a PC, you can see what the supply voltage it actually sees even if the ZXD says something different for the V at its output.

[Burgerman]

I think iCharger so no idea what he is looking at.

[fishinjunky]

I'm using a iCharger4010. When I say reading the voltage at the charger what I mean is I'm reading the voltages displayed on the iCharger display screen. I'm using a 24v 69amp psu.
What I'll do today is test with a multimeter the voltage at the cell terminals while charging.
It charges up to 3.6v without problems and amps drop off until it ďrops to the end current I set at 1% of 35amps. I was just concerned about the 3.8v the charger displays while charging.( it only shows 3.8 when charging, when not charging it displayss the same voltage as the balance lead on the display.

If the charger displays 3.8v output while charging then if I test at the terminals while charging with a multimeter and the multimeter shows 3.6v will ii be ok?

I tried different charging cables an same result

I just don't want to do anything catastrophic to the cell

But I understood going into this with the ICharger iits a territory with unknowns.

[fishinjunky]

I'm using a iCharger4010. When I say reading the voltage at the charger what I mean is I'm reading the voltages displayed on the iCharger display screen. I'm using a 24v 69amp psu.
What I'll do today is test with a multimeter the voltage at the cell terminals while charging.
It charges up to 3.6v without problems and amps drop off until it ďrops to the end current I set at 1% of 35amps. I was just concerned about the 3.8v the charger displays while charging.( it only shows 3.8 when charging, when not charging it displayss the same voltage as the balance lead on the display.

If the charger displays 3.8v output while charging then if I test at the terminals while charging with a multimeter and the multimeter shows 3.6v will ii be ok?

I tried different charging cables an same result

I just don't want to do anything catastrophic to the cell

But I understood going into this with the ICharger iits a territory with unknowns.

The charger only displays a 0.2v higher difference when charging at 20 to 35 amps. When charging at 15 amps the charger displays 3.65v when charging at 20 to 35 aammp the charger displays 3.8v