Overcharging will cause the battery to heat up internally and prolonged or excessive charging may cause a fire

 LiFePO4 Lithium Battery

 

3. Use the correct terminal mounting hardware

Use 20 mm long bolts for batteries 90Ah and above. 15 mm bolts for batteries 60Ah and below. If in doubt, measure the depth of the threads in the cell and make sure the bolt will be near but not touching the bottom of the hole. From top to bottom, you should have a spring washer, flat washer, and then the battery interconnects.

 

About a week after installation, check that all terminal bolts are still tight. Loose terminal bolts can result in a high resistance connection, robbing your EV of power and causing excessive heat.

 

4. Never overcharge/discharge your batteries!

The most common causes of premature failure of LiFePO4 batteries are overcharging and overdischarging. Even one occurrence can cause permanent damage to the battery, and such misuse can void the warranty. A battery protection system is required to ensure that no cell in your battery pack is likely to exceed its nominal operating voltage range.

For LiFePO4 chemistry, the absolute maximum for each cell is 4.2V, but it is recommended that you charge to 3.5-3.6V per cell, with less than 1% additional capacity between 3.5V and 4.2V.

 

Overcharging will cause the battery to heat up internally and prolonged or excessive charging may cause a fire.

 

Overcharging may thus occur as a result of

Incorrect installation of the battery protection system

Lack of a proper battery protection system

Infected battery protection system failure

 

On the other hand, over-discharging can lead to battery damage. If any battery is near empty (below 2.5V), the BMS must be disconnected from the load. Batteries may be slightly damaged below 2.0V, but are usually recoverable. However, a battery driven to a negative voltage will be damaged beyond recovery.

 

On 12v batteries, use a low voltage cutoff instead of the BMS to prevent the total battery voltage from falling below 11.5v without battery damage. Charge to no more than 14.2v on the other end and no battery should be overcharged.

 

Swelling only occurs when a cell is over-discharged or, in some cases, over-charged. Swelling does not necessarily mean that the battery is no longer usable, although it may lose some capacity as a result.

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