Kalkoff batteries again !

[One_Box]

I took delivery of a new 17Ah battery on 17th June from 50Cycles Bristol showroom.

On the 19th I set off on a "conditioning" ride on the POWER setting and after 40 miles the battery was nearly discharged. I took it out and it now looks like this : -


The casing has bulged outwards in way of the split, does anyone have a clue what has happened ?

The battery came fully charged with a test certificate and has not been dropped or mishandled. Current recharges = 0.

it is being returned to 50Cycles head office for inspection today. They won't do a straight swap for a another new battery and my info. is that they haven't seen anything like it !

I will keep you updated

 

[EddiePJ]

No idea about what's happened to it, but I wouldn't be keeping it indoors, and transporting it in a car could be just as dodgy.

 

[Wicky]

Good point on the logistics of returning what could be a potential UXB.

Is it going by courier or is someone from 50Cycles coming to collect it?

 

[derf]

Good point on the logistics of returning what could be a potential UXB.

Is it going by courier or is someone from 50Cycles coming to collect it?

FWIW - I have a woosh santa ana, the battery - after ten months of rattling through terrible potholes - developed a strange ammonia smell - I returned it to woosh (to their credit they replaced it, no questions asked, with a brand new one - so much for buying premium brands like kalkhoff for peace of mind I guess) - but here's the thing: royal mail would not transport it if I said it was a lithium battery - when I said it was a "lithium battery as part of a device" (I guess they must think a BMS keeps things safe) they were happy to transport it. I wouldn't have sent it if it were to be travelling by air.

 

[Deleted member 4366]

That's a strange fault. It's a shame that you couldn't open it to find out what's wrong. I guess 50Cycles will keep it a secret. When a supplier hears about an unusual problem with their product, it's natural be suspicious, but once they've opened it up and seen why it's bulging, the suspicion should evaporate. If it's a manufacturing fault, 50Cycles should replace it with a new one very soon. Please let us know what happens.

It would also have neen useful to measure the actual voltage because there could be other faults on your bike that caused it. Wht was your battery level meter showing when you finished your ride?

 

[mike killay]

What is the hole above the split?
Could it be simple mechanical damage?

 

[flecc]

That is an odd expansion. The sort of thing that is inside is shown below and I wouldn't expect enough lengthwise expansion of any 18650 cell that would cause that. If faulty, they usually expand sideways:

 

[Deleted member 4366]

I've never seen a 18650 cell expand and I must have disassembled more than 50 duff batteries with every type of 18650 cell.

 

[flecc]

I've never seen a 18650 cell expand and I must have disassembled more than 50 duff batteries with every type of 18650 cell.

I agree, I've only seen sideways expansion of other cells, including cylindrical, but never an 18650, hence my surprise at this one.
.

 

[One_Box]

Good point on the logistics of returning what could be a potential UXB.

Is it going by courier or is someone from 50Cycles coming to collect it?

TNT, their usual courier for this type of job.

 

[oriteroom]

Was this a replacement battery for one you had trouble with burn on the negative terminal after 6 weeks, or the loan battery they were going to supply?. Seems a few teething issues with these batteries! My wife's is only an 11amp, Osho has a 17A I think

 

[One_Box]

That's a strange fault. It's a shame that you couldn't open it to find out what's wrong. I guess 50Cycles will keep it a secret. When a supplier hears about an unusual problem with their product, it's natural be suspicious, but once they've opened it up and seen why it's bulging, the suspicion should evaporate. If it's a manufacturing fault, 50Cycles should replace it with a new one very soon. Please let us know what happens.

It would also have neen useful to measure the actual voltage because there could be other faults on your bike that caused it. Wht was your battery level meter showing when you finished your ride?

The meter on the battery itself was showing one flashing LED and the handlebar display showed virtually empty. The level had dropped progressively through the ride and was where I expected it to be. When the red button on the battery is held down rather than just being pressed it showed 5 LEDs ( I believe this gives a rough indication of condition but I may be wrong ).

 

[One_Box]

Was this a replacement battery for one you had trouble with burn on the negative terminal after 6 weeks, or the loan battery they were going to supply?. Seems a few teething issues with these batteries! My wife's is only an 11amp, Osho has a 17A I think

No, this was the brand new battery to replace the loan part !

 

[oriteroom]

What is the hole above the split?
Could it be simple mechanical damage?

It's just the access hole to one of the screws that keeps the casing together

 

[One_Box]

What is the hole above the split?
Could it be simple mechanical damage?

It is a hole for a recessed screw.

The casing is not just split but has bulged also which would indicate a problem within.

The battery has only had the test charge at 50cycles. I just hope a replacement will not be long coming !

 

[trex]

I've never seen a 18650 cell expand and I must have disassembled more than 50 duff batteries with every type of 18650 cell.

why do you assume it's made of 18650s?
it could well be made of pouch cells.

 

[flecc]

When the red button on the battery is held down rather than just being pressed it showed 5 LEDs ( I believe this gives a rough indication of condition but I may be wrong ).

This check is the battery capacity (Ah), as opposed to the charge content that's indicated by the short press.

Your five LEDs lit indicates it has the full capacity a new battery should have.
.

 

[flecc]

why do you assume it's made of 18650s?
it could well be made of pouch cells.

BMZ use 18650s in these Kalkhoff batteries, I posted a photo of their internal construction above.

Here's what they say about their 11 and 15Ah batteries for example, copied and pasted:

50 Cells | Type 18650:

10 Cells serial à 3,6V x 10 = 36 V

5 Cells parallel à 2,25 Ah x 5 = 11,25 Ah
5 Cells parallel à 3,00 Ah x 5 = 15,00Ah
.

 

[One_Box]

50Cycles phoned this afternoon to explain Company policy regarding defective batteries and their replacement... Fair enough.

TNT picked up the defective battery... we are making progress

 

[EddiePJ]

No, this was the brand new battery to replace the loan part !

Ouch!!!