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Old 08-08-2012, 03:08 PM   #11
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And after about a mile ride I rechecked voltages and the battery with the weak cell started at 5.2 and then quickly climbed back to 6.2.
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Old 08-08-2012, 03:22 PM   #12
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This was at the beginning of a charge cycle.

41.1 at control board and 40.3 at pack.
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Old 08-08-2012, 03:55 PM   #13
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It has made it to 44.1 at control board and 43.7 at pack.
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Old 08-08-2012, 03:56 PM   #14
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Quote:
Originally Posted by andy. View Post
It has made it to 44.1 at control board and 43.7 at pack.
And down to 10 amps. Initially at 21 amps.
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Old 08-08-2012, 04:37 PM   #15
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Cuts off at 44.3 internally and 37.8 at pack.
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Old 08-08-2012, 05:30 PM   #16
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Default Re: Batteries or charger

Two, maybe 3 different issues here.

1. A SG of 1.225 is only about 75% SoC. If you can lay your hands on a 6V charger, charge that battery by itself until the SG stops rising. (Or you can check the voltage every hour and charge it until the voltage stops increasing)

If it does not come up to where it ought to be, either the plates are either irreversibly sulfated or some electrolyte has been lost and replace with water. (Note: You don't normally loose any of the sulfuric acid during gassing, but it can bubble over if the cells are overfilled or the battery is tipped far enough for it to spill out.)

2. Having a different pack voltage at the battery pack and at the control board, tells me there is either a lot of resistance in the battery sense circuit, or you are using two different meters to measure them and the meters don't agree. (Or there is a lot of resistance in the wires connecting the dash mounted DVM battery meter)

3. Starting at 21A and dropping to 10A tells me the basic charger is working the way it is supposed to and the issues are in the control circuit that turns it on and off, or the battery pack.
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Old 08-08-2012, 05:33 PM   #17
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Had a typo on voltages 44.3 and 43.8 at pack. Basically .5 volts all through out the charge cycle. Still only took a couple hours at most.
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Old 08-08-2012, 05:55 PM   #18
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Default Re: Batteries or charger

0.5V is a huge amount of difference. About 10% SoC after resting, and I suspect it is even more significant during the absorption phase of the charge cycle.

Using the same DVM, the voltage at the main + & - terminal of the battery pack should be identical, repeat, identical with the voltage at the control board.
If not, there is a bad wire or connection somewhere.
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Old 08-08-2012, 07:15 PM   #19
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The numbers I have earlier were while it was charging, that is where the .5v difference is at.

Right now it is at 37.7 at the control board and 37.7 at the pack with the charger unplugged from the wall.
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Old 08-09-2012, 04:26 AM   #20
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Default Re: Batteries or charger

Quote:
Originally Posted by andy. View Post
The numbers I have earlier were while it was charging, that is where the .5v difference is at.

Right now it is at 37.7 at the control board and 37.7 at the pack with the charger unplugged from the wall.
The voltages are the same when there is no current flow (resting) and the voltage are different when there is current flow (charging).
Therefore, there is resistance in the wires and/or contacts in the battery sense circuit.
FIX IT!

The specific Gravity of the electrolyte in one battery is 1.225 while the SG of the other five identical batteries, is 1.3.
Therefore the one battery is sick.
FIX IT!

After fixing the two positively identified problems (either of which will cause an automatic charger to shut off prematurely), further testing and troubleshooting will be needed to determine if the charger is functioning as it ought to and if batteries that have never been fully charged, nor properly broken in, during the 14 months they have been in use, are salvageable.

I may be wrong, but at best you need only to clean the battery sense circuit and fix/replace one battery.
At worst, you'll need to clean the battery sense circuit, replace all 6 batteries and the control board in the charger.
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