Battery Build

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A Guide to Repairing a Lithium Iron Phosphate Motorcycle Battery

Ā  Ā  Welcome to the Cell Doctor channel. In todayā€™s video, we will explore the process of repairing a lithium iron phosphate (LiFePO4) motorcycle battery that is currently non-functional. A friend of mine reported that this battery was short-circuited. Although it still shows some indication of life with two lines, the voltage measurement reads 9.7 volts. We need to determine if it can receive any power.

Ā  Initial Diagnosis

Ā Firstly, we checked the voltage, confirming it reads 9.7 volts. However, the battery does not draw any current, indicating an issue. To understand the problem, we need to open the battery and inspect its internal components. Typically, these batteries contain a Battery Management System (BMS), and the fault could either lie within the BMS or the cells themselves.

Ā  Opening the Battery

Ā Opening the battery was straightforward. Upon removing the lid, we observed the balancing leads. The board is marked SMT H04 S LED LDVD O, indicating that it includes an LED board and balancing wires. We measured the voltage on these wires to assess the condition of the cells. The cells are encapsulated in silicon, which makes access difficult. However, we attempted to charge the cells through the balancing leads to avoid complete disassembly.

Ā  Cell Voltage Inspection

Ā The voltage readings showed 3.3 volts for one cell and 0.2 volts for another, indicating that one of the cells is dead. Specifically, cell number two is non-functional, while the other cells seem to be in good condition. We attempted to charge the dead cell by setting the bench power supply to 3.6 volts and connecting the leads. Unfortunately, the cell did not draw any power, confirming it is indeed dead.

Ā  Deeper Investigation

Ā Given the dead cell, we needed to delve deeper. Carefully cutting the silicon around the cells, we ensured not to puncture the good cells to prevent any fire hazard. Once the silicon was sufficiently removed, we extracted the battery. With the cells exposed, we found that they are spot-welded together, complicating the repair process.

Ā  Identifying the Fault

Further inspection revealed that cell number two had disconnected from its neighboring cell, causing the battery to fail. This disconnection needed to be repaired by soldering the cells back together.

Ā  Repairing the Connection

Ā Soldering these types of cells can be tricky, but we managed to make a good connection on half of the tab. After ensuring the connection was secure, we reassembled the battery and isolated the terminals with Kapton tape. We then reconnected the LED board to check for voltage. The state of charge indicator showed full, indicating the repair was successful.

Ā  Final Testing

Ā We conducted a final series of tests to ensure the battery was functional. The voltage now read 13.3 volts, and the battery accepted a charge of 3 amps. Additionally, we performed a discharge test at 5 amps, which the battery handled without significant voltage drop. The ultimate test was placing the battery back in the motorcycle to confirm it starts the engine.

Ā  Conclusion

Ā This video tutorial demonstrated the process of repairing a lithium iron phosphate battery with a broken cell connection. These batteries, utilizing pouch cells, are common in high-current applications but are more challenging to repair than cylindrical cells. Nonetheless, the repair was successful.

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Reviving a Junior Dirt Bike: 48V 13S 6P Battery Rebuild and Water Damage Repair

In this detailed tutorial, we demonstrate the process of rebuilding a 13S 6P lithium battery pack for a junior dirt bike that sustained water damage. Here’s what you can expect from the video:

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  • Battery Rebuild: Watch as we replace all the damaged cells with ones salvaged from other battery packs.
  • Time Efficient: The entire rebuild process took approximately three hours.
  • Cell Salvaging: Out of 65 original cells, we managed to salvage 64 and used them to construct a new pack by combining them with additional used cells.
  • Technology Insights: Learn about the Mega CNC for matching battery strings and the Megacell Charger for rigorous cell testing.
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Some of our newest products

Raspberry-Pi 4 Starter KIT-WHITE-4GB – MegaCnC Preinstalled

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$124.20
Ā Raspberry Pi Starter KitĀ 
Kit includes:
  • Raspberry Pi 4 Model B
  • with 4GB RAM
  • 5.1V, 3A power supply
  • 16GB Micro SD card
  • MegaCnC software installed
  • 1M Micro HDMI to HDMI cable
  • two-piece heat sink kit
  • molded enclosure (white)
  • getting started booklet
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48v Metal Box Kit lifepo4
48V kit lifepo4

48v 280ah Metal Box Kit

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$550.80$2 019.60piece
Elevate your energy storage solutions with our 48V Battery Assembly Kit, tailored for 16 LifePo4 cells ranging from 280Ah to 302Ah. This comprehensive package includes a high-capacity 200A BMS for superior power management, alongside essential assembly components like cables and screws. Ideal for building robust and efficient 48V battery systems for a variety of applications. Application : Home Energy Storage Battery  
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12V Battery kit Lifepo4 280Ah - 302Ah
12V Battery kit content

12v 280ah Metal Box Kit

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$226.80$594.00piece
This all-in-one kit includes a durable full metal box to protect and cool your cells, ensuring longevity and efficiency. High-quality M8 Terminal Connectors provide secure, low-resistance connections, while the state-of-the-art JK BMS with 1A Balance meticulously manages cell health, enhancing battery life and performance.

8 x XS12 Multi-Slot Combining Cable

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$17.28piece
8 x XS12 Multi-Slot Combining Cable. This cable is perfect for combining multiple slots from MCCPRO to charge or discharge large cells. This cable comes with 2 x external temperature sensors. Using 8 slots, you can achieve a total of 36A Charging and 24A discharging (16A discharging on MCCPRO-Hobby)

Alligator Connector with temperature sensor

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$4.32piece
This accessory is compatible with MCCPRO Hobby and Commercial version. It's designed to extend the cell testing capabilities to other cell formats such as pouch cells, prismatic cells or large cylindrical cells.

42V 5A Battery Charger for electric Bicycles, Scooters

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$75.60piece
This specialized charger is tailor-made for electric bicycles and scooters, ensuring a seamless and reliable recharge for your eco-friendly rides. With compatibility for various electric vehicle models, this charger is a must-have accessory for anyone looking to maintain their electric mobility. Keep your adventures going with this efficient and convenient charging solution.

Refrigerator ozone air purifier

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$32.40piece
 
The image features a compact and efficient refrigerator ozonizer, strategically placed inside a fridge. This small device is in operation, highlighting its role in purifying the air and eliminating unwanted odors within the refrigerator. The design of the ozonizer is sleek and modern, making it a subtle yet powerful addition to any kitchen appliance. The visual emphasizes the ozonizer's effectiveness in preserving food freshness and maintaining a cleaner, more hygienic environment in the refrigerator. This image appeals to anyone looking to enhance their food storage practices with advanced, health-conscious technology.

Car Ozonizer 12V/DC

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$12.96piece
This image features a modern, portable car ozonizer, neatly placed within a vehicle's interior. The device, compact in design, is shown in the midst of purifying the car's air, indicating its effectiveness in removing odors and improving air quality. Its sleek and unobtrusive appearance blends seamlessly with the car's environment, illustrating how technology can enhance everyday driving experiences without being intrusive. This visual is particularly appealing to car owners looking for a simple, efficient solution to maintain a fresh and clean atmosphere in their vehicles.
 
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