Soldering cells together

[flecc]

That's all you,can do realistically Griz, it's not practical to measure cell impedance etc, and in any case you'd need quite a few spares to be able to reject for that.

I think just matching voltage, then part charging and part discharging only the first one or two times is enough to bring the cells roughly into line before going into full charging and discharging.

Manufacturers don't usually match, putting the onus on cell suppliers or departments to supply from single consistent production runs, and that usually works.
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[Grizzly Bear]

Hi Flecc
tomorow we are having a soldering evening, you are of course invited. I found all those cells joined together when I stripped out my battery pack, a bit worrying, all that potential!! So I separated them all, now I have to join them all up again, and I'm not looking forward to it. At least I'll have 30 cells this time, my bike will go even faster! I think I'd better get my old crash helmet out!

All the best mate

 

[flecc]

Best of luck with that Griz, don't breath in the flux fumes!

As you say, it will be good to have the extra cell, which will give more power than you might expect pro rata. The loss of a cell the same disproportionate change, but to loss of course.
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[Grizzly Bear]

Hi Flecc
you won't be surprised to know that I understand.

Regards

 

[flecc]

Of course! You won't be catching ZX10s, but it's be a load of fun trying.
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[Grizzly Bear]

Hi Flecc and Ian
I have been breathing flux fumes all night, I'm not dead, but I now have a functioning battery pack again. Flecc if you don't hear from me in the morning, it will be safe to assume that there was a delayed reaction to the flux fumes. I have to report that the 120 watt soldering iron sold by Machine Mart is Mighty to say the least, and is now one of my favorite tools.

Regards

 

[flecc]

That's great Griz, let us know how the bike goes with the full cell complement now.
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[Ian]

Nice one Griz, I have to say I like Machine Mart.. full of big boys toys

 

[flecc]

Trouble is, I always want to say "How much for the shop?".
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[silversurfer]

home made battery packs

Hi folks, noted the activity on batteries. A few weeks ago I did a bit of fishing for info. on these forums and of course got some valuable guidance.

Been a bit busy lately but my plan is to build a 'get me home battery', a sort of 5 mile 'lifebelt' as my personel 'internal battery' is a bit damaged.
Bought 34 of those Lidel 4.5ah D cells. I reccon with 33 cells I will get about 38/39 volts charged up, to allow for some drop under load.
I agree with flecc, they may not be up to a high rate of discharge, so a bit of suck it and see, (If you see 34 cells on ebay you'l know they did'nt work!)

My plan is to use the cells in three 65cm (thats about 26" to us mature guys!) long; 40mm/1.5" dia. plastic water pipe tubes. With the batteries loaded inside, the pressure on the screwed end cap should load up the cells to make contact, like a giant police torch! The fittings caps etc are all avail. from the builders stockists.
Once wired up they will sit on the carrier of my Torq like a super sized toblerone chocolate bar! Anyway thats the plan, probably do it in November, when I get a bit if slack time.
On soldering, I have an ancient 150 watt 'Solen' iron, (still on rubber flex!), takes about a day to warm up but once hot it is the business. Emery the stainless battery contacts, in-solder-out within 3 or 4 seconds. You can't beat a big copper iron for these jobs.
Oh, by the way riding my torq is the most enjoyable experiance I have had for years, 200 watts of pure, stuka sounding power in my left hand. Clarkson eat you heart out !!! silversurfer.

 

[flecc]

A problem you'll find with 33 cells on the Torq, silversurfer, is that the quiescent full charge voltage will be initially at about 49 volts and as the battery cools after charge, settling at about 45.5 volts.

This is too high for the controller which will give a 7 flash LED signal to indicate the excessive voltage.

I've found the acceptance level on my Torq controller is 44.3 volts, and on the identical controller on my Quando, 43.7 volts. From this I deduce the specification limit is 44 volts. Yours is likely to be somewhere around that.

On my 33 cell Radical battery for the T bike, I use a multi resistor discharger to cream off the excess tio allow it to run if I need to use it soon after charging. If it's left for about 3 to 4 days before use, the natural NiMh discharge is sufficient anyway.

The details on having a 33 cell battery for eZee bikes are on my website and include some discharger details:

39.6 volt battery
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[derrick7]

Solder irons - electrical

I have just taken delivery of an 100w solid tip iron for £12.43 ANTEX & it is excellent. Model HP100.
They don't charge you postage!! Ordered on the 28/09/07 delivered on 29/09/07; a first class service & an excellent product, I wish some e-bike makers could emulate that sort of service!!
Welcome to Antex - Soldering irons, Soldering stations, Soldering accessories

Derrick - Llanberis

 

[silversurfer]

Hi flecc, my mind is going I think! I have just posted a reply to Grizzly bear's post on how his Lidel battery performed, as I could not remember where I did post this battery enquiry !!!
I note you very useful tips on 'over voltages'. Also discovered and read you uprated extra cells battery for a Torq, excellent. But mine is a Li-pol so that is why I am building a Ni-hi back up. There is a mine of information on this site, just A little confusing to select the correct forum, I may be guilty of 'spray' posting, not to be confused with 'fly' posting!
I will be away for over three weeks so some relief from my wordy posts ! Regards Silversurfer.

 

[flecc]

No problem Silversurfer, your posts are as welcome as anyone elses.

Enjoy whatever you're up to over the next three weeks.
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