Need some advice recovering some batteries

[pdarnett]

So back to the original thread. Status update on the original pack. I'm having to charge each cell very slowly and individually, all cells are near 3v so going to order the proper pack charger to top it off. In the meantime if my 5S balance leads show up in the post I'll do a balance charge on half the pack then repeat on the top half.
While I've been waiting on the charger I've been building some of the 1S4P 1850 packs.

 

[pdarnett]

Ordered the proper charger today, pack at 32v so looking good, plus got myself a powabyke x24 battery and charger that had some dead cells that I've just rebuilt with some good cells (only 3 dead ones to replace), nice cheap 6Ah spare to play with. Bit scary though, no bms in these things! Notice the new powabykes have a different battery these days.. maybe they had issues?

 

[jackhandy]

My missus' x6 battery got water in & killed the bottom cells: Turned out to be only 4.5ah & no bms so, yes, I'd say they had issues

 

[flecc]

It really was inexcusable to market batteries like these, not only without protection but many of them with 4.5 Ah cells although sold as 6 Ah. It wasn't surprising that the company failed shortly afterwards and had to be rescued.

Hopefully today's X model batteries are much better.

 

[pdarnett]

Well the cells in this one were 2200mAh Sanyos ones ( good job as that's the spares I had) rebuilt it back into the case today. Made some rubber seals for each end and heat shrunk all the connectors and joints inside. Just charging it today and give it a try. Well when the sleet stops!

 

[pdarnett]

Busy day and no point in going out in the sleet and hail. So did a ton on the batteries. Rebuilt the Powabyke one and gave it a sleek new abs sleeve to cover the battered aluminium one. Full charge ok and all the cell packs checked out. So a good spare to mess around with.

 

[pdarnett]

Plus got to work on the new bike. it's a Carrera Subway 2, an eBay bargain. Swapped out the forks for some rock shox and I needed V brakes on the front as the motor hand no disc mounts. Added the mudguards. Fitted the LCD and most of the wiring from the kit Dave sold me. The front wheel is a Cyclotricity 250w one from another forum member. Fitted the PAS, no room on the bottom bracket so had to improvise! The motor connector is a marine one, 9 pole. Then once together I sealed it with self amalgamating tape to keep out any moisture. The front light is some Chinese thing that's brighter than the sun ( has 4 18650's). Rear light is a standard LED thing.

Powered it all up fine from the Powabyke battery, loads of torque, just need for my triangle bag for the controller and some fine weather!

 

[Deleted member 4366]

Nice work. We don't have enough people on this forum doing a bit of DIY. We've got a long way to go to catch up what they do on the German one.

The motors that take discs are often the same, but with the six holes drilled and tapped in the disc side. As long as it's flat, you should be able to do the same.

 

[camerart]

I needed a battery to 'play' with my new wheel etc, and had to connect some more NI-MNs together to make up to 36V. I don't know what the tags are made of, but they definitely don't solder? I had to solder to the cells.

Just wrote a timing program, for firing the spot welder. Next, the electronics.

 

[El Champiero]

I am thinking of building a spot welder - what instructions are you using?

 

[camerart]

Hi El Champiero,

I'm making it up as I go along, all of my tests are in my previous posts in this thread.

Don't hold me responsible if you copy as it could be not good practice!

I'll keep posting my efforts.

Cheers, Camerart.

 

[pdarnett]

There's no mount holes on the hub motor so no disc I'm afraid. But the forks are better ones than were on the original bike anyway.

My last 3 bikes have all been DIY ones, I've got an Ezee Sprint as well, plus my daughter has an electric dutch ladies bike. Oh and I've got an electric scooter that I play on. My current work bike is pictured, that's the one the Subway will replace so it may turn up in the classifieds!



I'm embarking on a much larger project soon as well, building multiple bikes. Some may end up for sale so I'll post some details when I get them. Liquidation stock, probably about 8 - 10 different bikes, some mtb, some cargo, rear hubs front hubs and some mid drives.. Just waiting on the details and sorting out some storage for them. Wife not happy but I couldn't pass it up. Now having to buy her a new kitchen to make up for it!

 

[Deleted member 4366]

http://www.ledhacks.com/power/battery_tab_welder.htm

 

[pdarnett]

Well all things come to he who waits, got the proper charger today and put it on for a couple of hours...



Pack reads nearly 39v but I didn't run a full 5 hr charge but looks promising, will give a full charge when I've more time to monitor
.
So started on the other pack, all the cells bar one look like they're recoverable, all took a straight 3v charge no probs. The dead one is well and truly dead, seems a shame to leave it for the sake of a cell, so anyone know where to buy a single 3.7v 9Ah cell like this?



Cell measures 150mm by 85mm wide by just under 10mm thick, had a good look online but some close but not enough. No real markings on it to tell the manufacturer.

 

[El Champiero]

Ah - I already tried the ledhacks one - works OK with 0.10mm thick nickel but not 0.15mm thick nickel which is what most e bike batteries are made with. Copper electrodes don't work very well either. you need something a lot better like a chromium alloy or something. I need one with FETS and dual pulse firing. Building one is going to be a mission.

 

[El Champiero]

Well all things come to he who waits, got the proper charger today and put it on for a couple of hours...

View attachment 7757

Pack reads nearly 39v but I didn't run a full 5 hr charge but looks promising, will give a full charge when I've more time to monitor
.
So started on the other pack, all the cells bar one look like they're recoverable, all took a straight 3v charge no probs. The dead one is well and truly dead, seems a shame to leave it for the sake of a cell, so anyone know where to buy a single 3.7v 9Ah cell like this?

View attachment 7758 View attachment 7759

Cell measures 150mm by 85mm wide by just under 10mm thick, had a good look online but some close but not enough. No real markings on it to tell the manufacturer.

I would try looking on Aliexpress. You may well find cells like that on there.

 

[pdarnett]

Already went on there, most of the cells listed are low C ones for tablet PC's

 

[El Champiero]

thats a bummer - I'll have a look too later tomorrow and see if I can find anything.

 

[pdarnett]

Found and ordered some from Hobbyking, £8, so got two!

 

[El Champiero]

Found and ordered some from Hobbyking, £8, so got two!

Good work! I was actually just looking on the net as well for them.