240v Battery Charger for Lithium Upgrade

Discussion about any electrical topic except 240 volts. Solar, converters, inverters, lights, battery chargers, etc
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T1 Terry
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Re: 240v Battery Charger for Lithium Upgrade

Post by T1 Terry »

Toolman wrote: Mon Jun 26, 2017 7:35 pm Looking at that graph I reckon that Brian would have had a HOT shower that night :D
We ended up having to put a solar cut set to operate a bit high up the voltage scale because the thermostat would shut down the water heater and if Brian wasn't there to turn his air con on or simply turn off the solar the battery would auto disconnect because the voltage was not being effectively controlled. Basically the solar heated the water when the battery didn't require any more charging so what would have been waste solar charge was used for a worthwhile purpose.

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Re: 240v Battery Charger for Lithium Upgrade

Post by T1 Terry »

native pepper wrote: Tue Jun 27, 2017 7:18 am
T1 Terry wrote: Mon Jun 26, 2017 6:00 pm Probably easier to show on a graph that samples at 30 sec intervals. This shows what is actually happening while charging a battery pack that can be completely missed using the random multimeter testing method.
Brian's battery test day one.jpg

Looking across the graph it can be seen where one cell jumps to 3.6v before the control system stops the charging yet other cells (yellow line) still haven't reached 3.4v, when the charge rate tapered off at around the 3hr to 3hr 20 min mark you can see the yellow line is actually still showing that cell voltage to be only 3.38v or less yet the blue line keeps going over the 3.6v mark and triggering a stop charge alarm.
Just because you can't see it happening using your measurement method doesn't mean that it doesn't happen, it just means you don't realise it's happening.

T1 Terry
Have never seen my cells act like that in any way, I have a pretty good flux multi and with these balancers they keep the cells very close together, during charging the difference is less than .01v and by the time they reach capacity they are always balanced. This was not the case using bms and or switching relays which were tried many many years ago and dropped, because they tended to throw the cells balance around to much and to me switching off and on is no different to float and compensation charging. The problems in the past for me seemed to revolve around the use of multi phase lead acid chargers, since getting the bulk chargers, those problems have disappeared and there are no problems, the cells are in balance throughout the charge and discharge periods
As I said previously, just because you don't see it doesn't mean it's not happening. You really don't know if you have a cell run away as the 14v cut off is reached, nor do you know if the cells actually reached fully charged because you don't see how far the voltage drops when the charging stops. As the graph shows, there are 2 cells way out of balance to the other 6, yet all are within 0.02v of each other at the 5 hr mark when the sun stopped creating much charge at all. The few steps after that would be inverter load from the fridge cycling and possibly Brian cooking dinner with the induction cook top, the inverter runs 24/7.

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Re: 240v Battery Charger for Lithium Upgrade

Post by Toolman »

Why were those 2 cells so far apart at the start of charging? :? I would have thought that they would had started more like they finished.
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Re: 240v Battery Charger for Lithium Upgrade

Post by native pepper »

T1 Terry wrote: Tue Jun 27, 2017 1:31 pm As I said previously, just because you don't see it doesn't mean it's not happening. You really don't know if you have a cell run away as the 14v cut off is reached, nor do you know if the cells actually reached fully charged because you don't see how far the voltage drops when the charging stops. As the graph shows, there are 2 cells way out of balance to the other 6, yet all are within 0.02v of each other at the 5 hr mark when the sun stopped creating much charge at all. The few steps after that would be inverter load from the fridge cycling and possibly Brian cooking dinner with the induction cook top, the inverter runs 24/7.
T1 Terry
That makes no logical sense at all, of course you will know if a cell is running away, by simply checking cell voltages and what you describe and along with your graph, may happen in your type of system, but not in mine and if my flux 117 can't ascertain the true voltage of a cell, how can you. Been down the road of switching relays and active/passive BMS many years ago and the associated frustration and never ending system watching. Now have a simple 2 component system, that does the job better than anything else we tried, is yet to fail and works extremely well.

If you don't have a good active energy transfer balancing system, of course you may spend your time trying to balance your cells. Previous balancing systems I've used bleed cells down, which doesn't really work and wastes energy, But a balancing system that moves energy from cell to cell, is not wasteful but efficient, as it doesn't effect anything or have loses and seems to smooth things out much better.

Switching on and off charge may slowly balance your cells, but using a constant balancing system you never have those problems unless you have a failing cell. It's the same with using a single stage bulk charge controller, compared to using a modified but still lead acid charger, L/A all have tapered charging and lifepo4 don't handle tapered charging very well when they are reaching their capacity. On the other hand lifepo4 handle full charge until full very well and seem to perform much better under those conditions.

There are no failed cells in any of my systems and after spending a couple of years constantly watching them many times a day, the charging system and regime works, 9 years is a pretty good time line for usage understanding. To me in my technical ignorance, switching on and off charge, even if it is rapid, replicates a lead acid charge regime, especially when you read they use 14.4v as the upper charge cutoff for lithium and float to that. That seems like they think every lithium cell is no different to lead acid and li-ion parameters are the standard, lifepo4 and other lithium chemistries, have different charge regimes and voltage capacities.

The first time I used this system, was very nervous and watched 300amp coming into my system thinking I may end up with a load of junk after this, much to my mates delight. When the chargers switch off and the pack settled, which took just a couple of minutes the cells all sat at 3.45v and the pack voltage 13.8v. Every day since it has been the same, when we get back from travelling the first thing I do is check all cell voltages and they are all balanced. You can't ask for better than that for an outcome.
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Re: 240v Battery Charger for Lithium Upgrade

Post by SteveW »

I'm having a deja vu moment - I seem to recall 12 months ago a similar attempt to answer a reasonable question from a forum member. The person with the technical knowledge, and who runs a successful lithium power business making RVers happy, in attempting the answer the question was badgered by a person who, in the same paragraph, professed to be technically ignorant but repeatedly criticized the person providing the answer.
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Re: 240v Battery Charger for Lithium Upgrade

Post by bagmaker »

I reckon its great! We have a few brains in the country who have runs on the board, all trying acheive the same outcome - who have come up with different methods to do it. Pepper, T1, Julian -brilliant minds sticking their worik into the RV side. There are others doing similar things in boating and they have all mostly filtered down from the lunatics in Electric vehicles who really know how to push the boundaries :P

NP, the rapid switching charging regime is not to replicate balancing, its to turn a taper into digital. The chargers utilized are not capable of transmitting the amperage we need so they are used to switch a number of higher amperage relays. As the (lead acid but not running in that mode) charger senses the battery voltage rising to its required setting then it ramps down the "on" time causing increasingly rapid switching of the relays.
Balancing is another story, T1 sorts that in other ways. (I think)

Could you post more infomation on your balancing choices currently available? If I check ebay for example, I find a zillion Lifepo4 balancers.
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Re: 240v Battery Charger for Lithium Upgrade

Post by BruceS »

Most of those balancers on Ebay are designed with the intention of charging 2 or more SMALL batteries for remote controlled toys. (even big men's toys)
A lot of them don't start balancing till at least 3.6V and then at such a low rate they can't keep up with our BIG chargers.
IF they started at 3.4 and ramped up faster and faster till 3.9 topping out at around 100w or more they would be good!
I chose watts rather than Amps so they would be less confusing for 24V or 48V installs.
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Re: 240v Battery Charger for Lithium Upgrade

Post by Wilbor »

Have a look at the GNE cell balancer
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Re: 240v Battery Charger for Lithium Upgrade

Post by BruceS »

Thankyou Rob! Might see if they can make a 16S one.
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Re: 240v Battery Charger for Lithium Upgrade

Post by bagmaker »

Good one Rob!
It appears the GNE units can be linked, Bruce, there is a diagram in the web page showing 2 units servicing an 8 cell battery.
The A/B terminals appear to be able to configure to multiply.

Worth an email to them

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