Kaboom goes the cell!


Was testing a battery module from my Prius on a battery analyzer.  The test
plan begins with a several  minute no-load, then a 1C load for up to 1
hour, then a several minute no-load, then a charge at 1C until peak voltage
is detected.



After 3 minutes, a cell exploded that could be heard all over the building.



Best I can tell, there was a less than perfect connection to the battery
terminal.  The initial 1C load only lasted 3 seconds (when it determined
that the low-voltage had been reached).  So then, 10 minutes later it began
a 1C charge (on what was a full battery).  And we all know that charging a
full NimH battery will explode.



Lesson learned.  1) Hang around and WAIT for  the initial discharge and
WATCH that it is going correctly before leaving the test.

2) Always assume a battery may explode and do testing where it will do no
damage.



Programmers:  When programming battery analyzers consider a bad connection
on the DIScharge cycle that might give an erroneous indication of a
discharged battery and fault the test.  Do not then continue to the charge
cycle.



Bob, WB4APR
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