Not to draw this topic out too far, but I thought I'd post an image
that shows what I inherited when I bought the conversion truck and
began removing the cells for installation in my car.
This is large image, but I left it in the original resolution after
cropping so that the details wouldn't
Mr. Sharkey via EV wrote:
In an EV, we usually only get a single bolt and a flat mating
surface the diameter of a nickle to make a successful connection. In
building battery packs, we get to repeat that a hundred times over.
Seems unfair, but I think I said it previously, we got to work with
>> It is possible that the Noalox had become separated in the bottle
>> but as a long term industrial electrician who has never used
>> the stuff before, I decided to use the tried and tested method of having
>> bright clean (tight) connections.
That's always my first choice also, bright and
So good to read that you found it was caused by being simply forgetful. I go
over all the terminals two or three times as it is so easy to miss one in a
couple of hundred.
Previous posts mentioned using Noalox paste. I used to use it as advised on
various forums but have been burning out the
I torque my CALB 180's to 14.75 ft lbs, or 20 NM.
This is per EVTV specs.
Dennis
From: EV on behalf of jim--- via EV
Sent: Wednesday, October 2, 2019 10:18 PM
To: Electric Vehicle Discussion List
Cc: j...@k6ccc.org
Subject: Re: [EVDL] LiFePO4 Thermal Imaging
Cor van de Water via EV wrote:
The leaves do not need to contact each other in any other point than at the
battery terminal screw which compresses them into one flat ring.
Ah yes; good point. Sometimes they are actually insulated from each
other, such as in high current switchmode power
Mr. Sharkey said (in part):
> Soft aluminum and copper make me queasy when I have to test the
> threads. I played it safe and only torqued to 8 ft.lbs. Anyone know
> the official torque spec on Thundersky's?
No idea on the Thundersky. The large Telecomm batteries we use at work are 110
inch
>> Glad you found something!
Yeah, me too. I went all around the battery and tested torque on the
rest of the 74 bolts, and only found a few that needed an extra
foot-pound or two. The threads have been coated with anti-seize, so
there is good lubrication, but I'm really gun-shy (wrench-shy?)
Mr. Sharkey said (in part):
> Well, it looks like this issue may have been one of my own making.
> When I went to remove the cell interconnect strap, both bolts into
> the cell terminals were "just snug", not tight. Apparently I got
> distracted when completing the BMS card swap, and didn't
] LiFePO4 Thermal Imaging Opinions?
Well, it looks like this issue may have been one of my own making.
When I went to remove the cell interconnect strap, both bolts into
the cell terminals were "just snug", not tight. Apparently I got
distracted when completing the BMS card swap, and did
Well, it looks like this issue may have been one of my own making.
When I went to remove the cell interconnect strap, both bolts into
the cell terminals were "just snug", not tight. Apparently I got
distracted when completing the BMS card swap, and didn't torque the bolts.
The straps are made
e
> room. You are seeing nothing about its own temperature.
>
> Bob, WB4AAPR
>
> -Original Message-
> From: EV On Behalf Of jim--- via EV
> Sent: Tuesday, October 1, 2019 2:21 PM
> To: Electric Vehicle Discussion List
> Cc: j...@k6ccc.org
> Subject: Re: [EVDL
seeing nothing about its own temperature.
Bob, WB4AAPR
-Original Message-
From: EV On Behalf Of jim--- via EV
Sent: Tuesday, October 1, 2019 2:21 PM
To: Electric Vehicle Discussion List
Cc: j...@k6ccc.org
Subject: Re: [EVDL] LiFePO4 Thermal Imaging Opinions?
Yes. Heat is going to con
Thanks everyone for the thoughtful replies. I'm very hopeful that the
problem is something external that I have control over, rather than
internal, which I don't. I'll be putting lots of attention into that
terminal, strap and hardware tomorrow. It will be embarrassing if it
turns out to be
lectric Vehicle Discussion List
Cc: Peri Hartman
Subject: Re: [EVDL] LiFePO4 Thermal Imaging Opinions?
Wow, hat's a great observation. Question: is it significant that the IR
image also shows heat emanating vertically, appearing to be relatively
uniform ?
Peri
-- Original Message --
From:
If you had a proper BMS like the Elithion system that I have, it would
show you the exact temperature of each cell and warn you of over
temperature.
On 9/30/2019 11:57 PM, Mr. Sharkey via EV wrote:
Time to turn up the dial on the technical channel.
After converting my car to a lightly-used
-Original Message-
From: "Peri Hartman via EV"
Sent: Tuesday, October 1, 2019 10:53
To: "Electric Vehicle Discussion List"
Cc: "Peri Hartman"
Subject: Re: [EVDL] LiFePO4 Thermal Imaging Opinions?
Wow, hat's a great observation. Question: is it significant
.org"
Sent: 01-Oct-19 10:36:24 AM
Subject: Re: [EVDL] LiFePO4 Thermal Imaging Opinions?
A close-up of the cell, looking from the front of the pack. It's been
photoshopped to blend the IR image with the visible image to provide some
perspective of the actual appearance:
http://www
> A close-up of the cell, looking from the front of the pack. It's been
> photoshopped to blend the IR image with the visible image to provide some
> perspective of the actual appearance:
>
> http://www.westlanetv.org/~sharkey/evgfx/Hot_Cell_2.jpg
Carefully check the connection on that cell
I have always thought temperature could be used in this way.
Sent from my iPhone
> On Oct 1, 2019, at 1:30 AM, Gary Krysztopik via EV wrote:
>
> Sorry, no help to you but I always wondered if thermal imaging could be
> used for a cheaper/simpler? BMS (assuming one had a clear visual of the
>
I had a loose connection on my pack. It heated the cell to failure before I
found it.
Sent from my iPhone
> On Sep 30, 2019, at 10:57 PM, Mr. Sharkey via EV wrote:
>
> Time to turn up the dial on the technical channel.
>
> After converting my car to a lightly-used set of Thundersky 160's,
I agree with Marco that it is quite likely a dirty/corroded connection
between the strap and the cell. This is more common than most folks realize.
Remove the strap. Clean both surfaces with Scotchbright. Apply a thin
coating of NoAlOx to the terminal and to the bus bar. Reassemble.
You
Sorry, no help to you but I always wondered if thermal imaging could be
used for a cheaper/simpler? BMS (assuming one had a clear visual of the
entire pack).
On Mon, Sep 30, 2019 at 9:08 PM Mr. Sharkey via EV
wrote:
> Time to turn up the dial on the technical channel.
>
> After converting my
Are you sure it is an internal cell failure and not just a loose or dirty
connection within the bussbar? The heat on that image looks only on one area
from the whole cell. Keep in mind that those ‘prismatic’ cells comes on tens or
hundreds of thin rectangular layers with the same shape of the
How much warmer is that cell than surrounding ones?
1 or 2 deg is no reason for panic, just keep an eye on it. 10 degrees and
it is wise to replace it soon.
Internal resistance is one of the best indicators of future failure.
Cor.
On Mon, Sep 30, 2019, 9:08 PM Mr. Sharkey via EV wrote:
> Time
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