BULGED BATTERY MODULES? NEVER SEEN THAT BEFORE

Try using a long clamp that can span the length of the battery It is definitely possible to get them back together if only a few are expanded.

 

You mean span the width of the battery. As far as bolting it back together Its not a length issue is a width issue?

I think once the battery is distended its done? The case is stressed.

 

I think its too late to reply but you can get them back. I had the same issue i put the fan on in the cold and cool down them to get them back on the normal condition. they are flexible unless they are way swell

 

Wow, talk about a hot mess!

 

Now i got
P0A9E. Temperature sensor circuit too high

 

Go back and look at the sensor and wires.
Make sure they are not damaged.
Replace as needed.

 

Thank you Eric, I replaces whole wire harness for temp sensors and its good now. Take care

 

I just about had a battery meltdown myself. Had a camera watching the pack and fortunately the expanding pack causes a cable to switch position and trigger motion alert where it drew a square around the motion and I noticed the pack swelling. I was charging at around 4amps which I have been doing fine with, but forgot today was a very warm day in the garage (95F). As I was there I noticed a second pack starting to expand so I was able to disconnect. I have since devised an anti-swell trigger that stops charging at any sign (1mm) expansion while under compression. Fortunately for me both packs return to normal size within 2hrs of cooling.

Picture: [Pack starting to swell, caught early]

 

Question. I cycle batteries charging at 2Amp. After discharging them to 6V
Around 5000mAh I get swelling like above. Is it OK? I try to charge up to 7000mAh

Temperatures of other batteries - 20C, batteires that start expanding around 25-30C

Should I change something or it's normal? They compress back after cooling..

 

Yikes!!! Two amps for a single module? I've never disassembled a battery to charge individual modules. My charger charges then entire pack at a third of an amp.

 

No they don't "compress back after cooling". Bulging ONCE makes them garbage. You are putting them in a system where they see 120A currents repeatedly. Bulging means you have broken the internal module goop essentially. There is no knowing if it is all cosmetic (very unlikely) or you have now caused pinhole shorts to open up that when you're cruising down the interstate decide to blow through and start smoking into the cabin.

2A is fine WITH COMPRESSION. Otherwise stick to under a half amp. Our modules on the other hand have a metal cylindrical shell. No compression required, they are already and always under the mechanical stability they need.

 

What does it mean "WITH COMPRESSION"? I am charging them assembled in a pack. Does it mean compression? I see them bulging but then they return to normal once cooled..
#3 shows how it is expanding.