new tester build


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100kwh-hunter

Active member
Joined
Mar 2, 2019
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1,388
I really regard that i sold my "old" tester, but here is tester 2.0(similar to tester 1.0...)
the story will come between the pictures and when i have the stuff (board) up to testing, this one i will keep updated, for the ones that are willing to build one and test on every aspect, this is for you.....big thanks to @Wolf
After harvest to test naked cells

1. find the specs, test IR!!!! and V below 2.5v just throw them away.
Label each cell with #+1 number and put that number onto cell and ure xls database, with datasheet numbers( exls will follow)
2. charge them to 4.2 with any tp.
3. discharge them to 2.8v with a zb (below 50% soh...throw away, but you can use them if your powerwall is big enough)
4. charge them to 4.2 and store them for at least 2 weeks.
4.1 check v before storage.
4.2 check v after 14 days storages...
Ones that drop 0.2v....throw away..(those are self dischargers....but you can use them...0.4v drop....done throw away)
5 discharge to 3.3V storage V..
In my memory there where 7 points to get rid of bad cells.....so i forgot two....keep on reading and figure out with me.
It will come back.
In the meantime i am building a tester that is ruling out the wanna be bad ones....

Oke here is the first start of the building process, testing proses wil come later.
20230708_165548.jpg
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20230708_193101.jpg

So lets make enough trays to go with 14 days to test v dropping (yes i need 6 more...they are on there way.)

Shopping list will come also.

With best regards Igor
 
Oke story continues....
With help of the extra hand of my wife thing with soldering goes very quick.
Hold a single string of wire heat it up and put the right amount of solder.....by one person....

Any way a update for those who want to build also.
20230711_182244.jpg

Thanks to my wife a extra hand is speeding up the proses. (35 total needed!)
20230711_182941.jpg


A female is attached to a board, i stick a male in on it en we solder.

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20230711_182420.jpg

Rest of the trays are coming.
Solder solder solder and solder, like one of the first vids hb powerwall, from our own pete.

In the first pic you will see two of them done.
I just need 8 stations to test but i need also 14 trays for waiting on v drop, is 22 total of trays minimum.
Everything will get clear as i build my tester 2.0(actually 3.0), i will not hide one detail, if you have any questions feel free to ask, if you feel to correct me or want to improve my tester, please feel free to do so, please.
This will be a long one, i will stop if the tester is complete and running incl all safety!!!

With best regards Igor K
 

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Smal update...it is a awful lot of work...getting older is no fun...my eyes are going a bit backwards...need reading glasses.
S**T
Still not done
20230716_172406.jpg

some zb's for discharging
20230716_171814.jpg

tp's for charging
20230709_184305.jpg

tacking the wire for the trays that is holding the cells
20230723_181025.jpg

soldering station for trays and stations with different tasks...
Different tasks: tp, zb, v measuring, ir measuring, discharging and what ever
20230723_180924.jpg

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Out of picture station one ir + v measuring.

Station two charge to 4.2 v
station 3 discharche to 2.8 v to get a Ah thus a soh
station 4 charge again to let them sit for two weeks to find any self-dischargers.

station 5 is for a brief v measurement, it is used 3 times before a cell can enter my Powerwall, to keep track on there doing.

station 6 is for charging a pack of 20 cells
station 7 is for discharging a pack of 20 cells to 2.8 v to get the total Ah
station 8 is for charging up to 3.3v for storage.
and a station for those bad cells to draw them empty.

Well this is the balance for now, will keep you updated.
Btw i ordered those heat fuses, when they warm up to 65C they will blow, end of story for any heater.
Those fuses will also get imbedded in a pack of 20 om top of each cell fuse of 1A
Yes this will be a very safe Powerwall.
Get heaters out, get self-dischargers out, get below 75% soh out get what ever is not wanted out!!!!

Will keep you updated.
With best regards Igor

Ps the designation for the stations are subject to change as the project is moving forward, one test at the time per station.
I want ridicules safe 2de hand cells....
 
Making progress, big progress!
Tester is not by long shot done, still waiting for some components from China.
Slowly i will get where i want to be.
Was busy with soldering those trays for 3 full days....got 17 ready.
The tester is "operational" and already in use.
20230813_093341.jpg

When it is done i will describe every single station.
The end goal for me is to have/do every day (continuity) 10 tested cells, every day 15 minutes before walking doggies.
 
Yes, fully functional....
Had some troubles with soldering and yes, some solder drippings on one of the zb's (discharger).:oops::rolleyes:
And some short in a charger.:eek:

20230816_125520.jpg


All is done incl several "helping" pieces.
Station one:
20230817_083700.jpg


Ready to test on IR and a piekview of the V, when all is in their limits, they will go into their tray and will receive a number.
Those numbers will go into a exls sheet.
Thanks to the hard work of @Wolf it made my cell logging so much easier!
Just type in the cell "name" in the search function of xls of wolfs data.... dinner is served! With all the date you want.
Purpose of this station
Find odd IR and below 2V they are out.


Station two:
20230815_125707.jpg

20230815_125644.jpg


This is the first time charging with the TP's.
The wooden board that is covering the cells have some heat fuses on them, they blow at 65C
Those fuses are in the line between the power supply wire and the tp, so i a cell wants to heat up, it will cut of the power and i have to replace the fuse.
This is just some extra safety for me.

To solder those heat fuses i used a glass of water, soldering them without......
20230815_084313.jpg

Nah not done, they quickly heat up above 65C.


20230815_103110.jpg


Station three:
20230817_083729.jpg


Discharge them to 2.8V and then i write the outcome into the exls behind there corresponding number.
50% of the original capacity is out. (soh%)
Between 50-70% and 70-80% soh i will keep them for other project or experiments.

Then the tray is moving to station number four.
20230817_083740.jpg



Where they get again a full charge.

Station number 5:
20230817_083751.jpg


Here i write down in the exls the voltage of the cell (after 24 hour settling)
(As you can see those where low v cells, is a experiment. IR was spot on, soh was above 80% and they did not heat up.)
(One tp decided to charge a cell up to 2.61 volt.. replaced the tp.)

Station number six:
20230817_094914.jpg


Here they go in for there waiting period of 14 days, to catch some self-dischargers.
After 14 days i check the v again.

Death row.
All the cells that are below 50% soh or odd IR or heating or below 2V or leaking or dented will go to station number seven, i call this one: death row:
20230817_083907.jpg

It has its own power supply because i needed 12V for the ventilator.
Also needed a extra psu for the main volt and amperage meter.(after the main psu 5v 30A)
Inside the wooden box there is a small cpu fan and some resistors.
The tp that is charging the 4 cells is connected to the main 5V line.
I can read from the meter what is going on: 0v and 0A is the end goal.
Max discharge 2.8A

All the good cells when i have enough will be paste and copy into repacker.
When the packs are assembled, i charge them up to 4.2v
20230817_083923.jpg


Then i discharge them to 2.8v to get a total of their storage capacity.

20230817_083929.jpg


After this charge back up to 3.3v for storage.

20230817_083950.jpg


I also use those last three stations to test my nimh packs.

But hey Igor we mis something.
Yes you are right, but i dont think it is needed.
After 14 day resting to find any self-dischargers i don't think it is needed to discharge them to storage voltige.
Was in the original planning btw, look at the empty spot on the board.

What I would like to add/change:
Add some diodes for wrong polarity connection and not to let the stations interfere with each other.
Get those volt meters at 12v line, incl a diode per meter.

So every day 10 mintus of writing down in my exl, testing IR and shifting the trays to their next station, every day 10 minutes and every day 8 to 10 good cells...every day.

I hope you liked this project write up and that it can help someone.

With best regards Igor.
 
39​
icr18650-26h​
2600​
2469​
94,96%​
7-16 ohm​
53,9​
408​
08-08-23​
412​
22-08-23​
40​
icr18650-26h​
2600​
2460​
94,62%​
7-16 ohm​
54,9​
418​
08-08-23​
415​
22-08-23​
cell​
name​
capacity​
capacity​
soh​
IR new​
IR now​
V before​
V after​
Date in​
V checkt with​
date out storage​
difference​
number​
new cell​
now​
storage​
storage​
storage​
ZB​
in V​
41​
icr18650-26h​
2600​
2566​
98,69%​
7-16 ohm​
57​
415​
09-08-23​
416​
23-08-23​
42​
icr18650-26h​
2600​
2506​
96,38%​
7-16 ohm​
56​
415​
09-08-23​
416​
23-08-23​
43​
icr18650-26h​
2600​
2547​
97,96%​
7-16 ohm​
56,6​
418​
09-08-23​
414​
23-08-23​
44​
icr18650-26h​
2600​
2563​
98,58%​
7-16 ohm​
56,1​
418​
09-08-23​
416​
23-08-23​
45​
icr18650-26h​
2600​
2550​
98,08%​
7-16 ohm​
56,5​
411​
09-08-23​
416​
23-08-23​
46​
icr18650-26h​
2600​
2538​
97,62%​
7-16 ohm​
56,2​
411​
09-08-23​
416​
23-08-23​
47​
icr18650-26h​
2600​
2577​
99,12%​
7-16 ohm​
55,8​
418​
09-08-23​
412​
23-08-23​
48​
icr18650-26h​
2600​
2494​
95,92%​
7-16 ohm​
57,4​
411​
09-08-23​
415​
23-08-23​
49​
icr18650-26h​
2600​
2527​
97,19%​
7-16 ohm​
57​
411​
09-08-23​
413​
23-08-23​
50​
icr18650-26h​
2600​
2466​
94,85%​
7-16 ohm​
57,1​
418​
09-08-23​
415​
23-08-23​
51​
icr18650-26h​
2600​
2591​
99,65%​
7-16 ohm​
56,6​
411​
10-08-23​
24-08-23​
52​
icr18650-26h​
2600​
2532​
97,38%​
7-16 ohm​
55,6​
411​
10-08-23​
24-08-23​
53​
icr18650-26h​
2600​
2571​
98,88%​
7-16 ohm​
57​
415​
10-08-23​
24-08-23​
54​
icr18650-26h​
2600​
2576​
99,08%​
7-16 ohm​
57,6​
418​
10-08-23​
24-08-23​
55​
icr18650-26h​
2600​
2559​
98,42%​
7-16 ohm​
57​
411​
10-08-23​
24-08-23​
56​
icr18650-26h​
2600​
2540​
97,69%​
7-16 ohm​
57​
408​
10-08-23​
24-08-23​
 
Tester will be expanded and will be "in Progress".
First station a unknown cell will see is discharge.

Only a fully discharged cell when entering charge station will heat up.
So there are two ways to catch a heater by his b**ls:
IR and charging.
Both methods can work separatly, but you will need both to get 100% result.

So first discharging and expanding my tester.

Expanding my li ion tester in two ways:
There are too many friendly companies that are willing to "give away" or save for me there 18650's(laptop, e-bike, e scooter, e-moppet ect e)
I am not behind my work, i have work in stock!!!!!!!!!!!!
So i need to ramp up my testing.
And there is a little change in my testing field/method, first IR and discharge!
Then charge with heat fuses on top of them.
Better safe than sorry.

Oke second add on:
nimh cells.
Will need cc/cv charging after discharge of course to 0.9V
Need charge to 1.35V to stay below delta(change in V)
Delta V and T is a other story separately regarding NiMh.

Different format li ion cells 3.5A each up to 15A each.
Now this one i alreade have...kind of?!?!?
I have a separate part of my tester for pack testing, i could use that section....
I did nt give it a lot of thought to adopt, but i think it can be done, why not big A is big Ah.

Second thought:
To wake them up, a first complete cycle.
Discharge and charge on those testers with heat fuses on them?


Then the cells will go to my acual tester(first IR, mandatory!)

I really would like to hear your thoughts about those extensions.
Regarding NiMh, 18650 and different format li ion cells.

With best regards Igor
 
I have a few of those ali-testers, they work pretty well, they are in the same category like those HW-586, just easier to use - my Opus testers started to die one by one - I tried to change the resistors but after a few weeks they also burn out... I have build my own tester with an Arduino and 10x1ohm resistors to get it as accurate as possible, but.... it's a lot of work and they end up being way more expensive than the China testers...
 
I really like the four-cell tester you posted the link to above (and repeated here). Had this been available when I was testing 100s of cells I would have much preferred it over the Lii-500 I have. The Lii-500 only records charge capacity, not discharge capacity which can be substantially different in many cases. In turn, I did pick up this tester which has quickly become my favorite but is meant for one cell or pack at a time which is fine for my e-bike packs and LiFePO RV batteries but not really for battery farms.
 
Yes a work in progress.
I extended my tester with a extra station.
This station is mainly for the new retrieved cells.
If you open several packs, most cells are around 3.7-8v some are around 4v even 4.3v
Some cells are down to 2v
ect.
To avoid trouble and give every cell a fresh good start into my tester i dont even look but discharge all cells that are above 2.8v to 2.8v.
This has a benefit that if a cell is a would-be heater, i can catch him in station one of my tester.
Comen sense of IR (Is always your nr 1 test) is also a big help to avoid heater, self-dischargers and low capacity cells.
After the first discharge is complete i write down all the v in my exels, cous not all of them are above 2.8v.
Even some 1v and 2v cells with good IR readings are fine cells.
So i started to test every cell!

Second part of the new extra station.
That socket has all the connections soldered together, so it makes one big cell.
So the cells will charge and wake up the sleepers and put in a charge -if necessary- to 2.8v.
After this they will have a 12 hour rest.(must be on 2.80 minimal)
Then i will check again on V any cell that is below 2.7 v is out.

This method will also help to keep my tp's alive.
I have a suspicion that low v cells are a to big hassle for the tp's 4056....btw 5100's are on there way to me.

20231008_095653.jpg

20231008_123822.jpg

yes i need to quit smoking.

20231008_123950.jpg

In colum M i write down the first numbers after the first discharge.
20231008_124115.jpg


Colum B is the cell type with the max discharge (ontladen tot) mah and ir.
So if i type in any cell type it will bring up the data that i need for testing
In collum C i write the fabric mah.
In collum D after the discharge test i write the outcome, in collum E it will be the calculated SOH, witch one to keep and witch one is going to death row.
In the case of the cells that are shown in the picture, there is no known IR (or i misinterpret Wolfs exls!)

When all the tests are done all cells are out that where to low on capacity, odd ir, self-dischargers, dented and heaters ect.
Heu...dented cells, yes, i test them for learning purposes. they tend to have a lower capacity then their brothers and sisters.

On this way i can do every morning before i go to work and every evening before dinner, sift all the trays up with one position.
With every sift up, i take out the bad ones, yes it happend that a tray starts full and just one can go into the 2 weeks waiting room.
20 cells a day, fully tested is costing me 2 times a day 5 to 10 minutes.
If a tray is done after two weeks of resting, i will see the last self-dischargers. 0.2v drop or more----->death row
I must admit btw, those red ones dont make me happy.....:rolleyes::(:cry:

I think i tweaked the process enough
When i receive a new batch of laptop cells i will also keep track of the manufacturer.

Thanks for reading, any comment, thought or question is welcome.

With best regards Igor

Ps the laptop is a very old one and only have to do is that xls, so some saw dust if blown out once in a while is no problem? the whole stuff is in a corner of my woodworking shed and i dont always put the plastic on:eek:
 
Hi, I am newbie for this. I have a question. Can we control discharge current for Zb2l3 like CC 1.0A starting from 4.2v way down to 2.75v? Thank you
 
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