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Develop ultra capacitor power supply and LiFePO4 battery power supply
Develop ultra capacitor power supply and LiFePO4 battery power supply
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Old 21st September 2019, 06:58 AM   #701
nielsek is offline nielsek
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Quote:
Originally Posted by alazira View Post
Start systematically measuring from (+)BT2 to the (-) of the other batteries to determine where the problem is.
(+)BT2 to (-)BT2 - 3,25v
(+)BT2 to (-)BT10 - drops from around 3,2V to 0
(+)BT2 to (-)BT9 - drops from around -0,2V to 0
(+)BT2 to (-)BT8 - drops from around -3,2 to 0
Exactly the same situation when measuring from (+)BT5 to (-)BT4/3/1

While doing the measurement and letting (+)BT2 to (-)BT10 drop down to 0 (in about minute or more) the next ones measure differently:
(+)BT2 to (-)BT9 - starts dropping from -3,xV to 0
(+)BT2 to (-)BT8 - drops from around -6,x to 0
Same thing on the other side, starting from (+)BT5 to (-)BT4

I can't make any conclusions from that, what about you guys?
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Old 22nd September 2019, 12:59 AM   #702
alazira is offline alazira  United States
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If (+)BT10 to (-)BT8 =9.9V then the issue is with BT2. Look closely at the battery terminals and remove any plastic in the center.
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Old 23rd September 2019, 09:44 PM   #703
nielsek is offline nielsek
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Quote:
Originally Posted by alazira View Post
If (+)BT10 to (-)BT8 =9.9V then the issue is with BT2. Look closely at the battery terminals and remove any plastic in the center.
Just to be sure I re-soldered the battery holders. Pushed the holder terminal (metal part) down while soldering. I hope this is the right way to do it.
To be honest, I don't exactly understand the "barely elevated plastic in the center of the negative terminal causing discontinuity".
Here is what I discovered:
When measuring voltage from holder terminals, not touching the batteries but only holder terminal, all give correct reading of 3,25V (when unit is ON!).
But when pushing down and forcing the holder terminal against the battery, the power supply does similar clicking sound, like when turning on. This happens with multiple battery holders, but not all.
Also I'm able to create the same clicking noise while gently pushing the battery holder sides (+ & -) with fingers, pressing the terminals against battery.
So does that mean, that there is problem with battery connection to the holder terminals? Not sure how I can fix this. Tried to bend holder terminal to provide more force but this did not resolve the issue.
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Old 23rd September 2019, 09:53 PM   #704
wealas is offline wealas
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The plastic cover of the battery sticks out at the bottom so the metal plate effectively sinks lower and the battery holder terminal might not be making contact. It seems that has been a problem for few people and might explain the clicking sounds when you are pressing on the holders.
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Old 23rd September 2019, 10:04 PM   #705
alazira is offline alazira  United States
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Quote:
Originally Posted by nielsek View Post
Just to be sure I re-soldered the battery holders. Pushed the holder terminal (metal part) down while soldering. I hope this is the right way to do it.
To be honest, I don't exactly understand the "barely elevated plastic in the center of the negative terminal causing discontinuity".
Here is what I discovered:
When measuring voltage from holder terminals, not touching the batteries but only holder terminal, all give correct reading of 3,25V (when unit is ON!).
But when pushing down and forcing the holder terminal against the battery, the power supply does similar clicking sound, like when turning on. This happens with multiple battery holders, but not all.
Also I'm able to create the same clicking noise while gently pushing the battery holder sides (+ & -) with fingers, pressing the terminals against battery.
So does that mean, that there is problem with battery connection to the holder terminals? Not sure how I can fix this. Tried to bend holder terminal to provide more force but this did not resolve the issue.
Good move resoldering, that would have been my next suggestion. As for the connection issue see this post
Develop ultra capacitor power supply and LiFePO4 battery power supply
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Old 23rd September 2019, 10:28 PM   #706
nielsek is offline nielsek
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Visually all the connections look good, made some photos.
If the connection would be bad, then measuring from the terminal (when unit is ON) should give 0, but not 3,25V. All of the readings are OK.
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Old 24th September 2019, 12:35 AM   #707
bigpandahk is offline bigpandahk  Hong Kong
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Quote:
Originally Posted by alazira View Post
Good move resoldering, that would have been my next suggestion. As for the connection issue see this post
Develop ultra capacitor power supply and LiFePO4 battery power supply
I experienced this before and was caused by cold soldering of relay. Re-solder all relays and see if it solve your problem.
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Old 25th September 2019, 08:14 PM   #708
nielsek is offline nielsek
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Quote:
Originally Posted by bigpandahk View Post
Re-solder all relays and see if it solve your problem.
Thanks for the suggestion. Did that, but no change. One of the relays seems to be damaged. I didn't notice it before, so not sure, how long it's been like that. Added a photo.
I should probably change it? Any hints, how to get it removed. It' has 8 connection points :-)
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Old 25th September 2019, 11:40 PM   #709
Greg Stewart is offline Greg Stewart  United States
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Develop ultra capacitor power supply and LiFePO4 battery power supply
Having tried to do that, I found it is nearly impossible without damaging the board. I had used solder wick to remove all of the solder from the board bottom side of the relay pins and pins on the top side were still soldered to the pads there. I could repair the board, but don't recommend this.

Ian may have a better suggestion. Me, I'd go buy 2-3 of those relays, then use a pair of pliers to crush one apart from the top to see how they break. Then I'd VERY CAREFULLY do that with the damaged one on the board to get down to where I could unsolder and remove each pin seperately.

Wait until you hear from Ian before attempting this! Again, he might have a better idea!

Greg in Mississippi
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Old 26th September 2019, 01:55 PM   #710
iancanada is offline iancanada  Canada
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Develop ultra capacitor power supply and LiFePO4 battery power supply
Quote:
Originally Posted by nielsek View Post
Thanks for the suggestion. Did that, but no change. One of the relays seems to be damaged. I didn't notice it before, so not sure, how long it's been like that. Added a photo.
I should probably change it? Any hints, how to get it removed. It' has 8 connection points :-)
Hi nielsek,

What happened to it? Poor relay

The PCB of LifePO4 board is very special. It has double thickness copper layers (For high current application).
What Greg said is correct, it's really hard to replace it. You will need a Vacuum desoldering gun. Can you access that tool?

Regards,
Ian
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