I`ve continued bottom balancing the cells as my battery box and it's mounting continued. My target is 2.750V plus or minus 5 mV. I got through all 14 yesterday and I was pretty close. 6 of the 14 cells needed energy drained away. It was not very much - I used 10 ma-h for all of them.
The batteries rose slightly after resting overnight. Cell 10 is the lowest at 2.760V. Cell 07 is 2.761V. All of the other 12 cells read 2.763V, 2.764V or 2.765V. That`s close enough for me. I`m getting a bit tired of this little procedure!
The lead batteries were connected (during testing) together with cables that I had cobbled together from salvaged motor connections. I have now built cables the correct length, and made the battery connections `permanent`. This involved removing the corrosion from the battery terminals and from the battery straps. Then I bolted the straps to the batteries in sets of 4. This made it pretty easy to move the batteries into the battery box with a bit of packing material around them so that they can take some vibration and some shock (bumps). Finish the last 3 terminations and the batteries are in the box. I need to make a spacer to hold them tightly in position (the box is too long). I may add another fuse internal to the battery box, to protect against a short circuit in the cabling that runs from the battery box to the High Votlage Junction Box (HVJB).
I`ve got the battery box mounted in the Electric Motor Module frame. The battery box cover and the tie-down for the cover still need some work.
In this design, all cables go through the High Voltage Junction Box (HVJB) or the Low Voltage Junction Box(LVJB) (or both). No two devices are directly connected together. The idea is that you can replace any part with a functional equivalent and deal only with that part, and the two junction boxes.
I`ve done some video, but I have not gone through the pictures yet.
Saturday
Demo Aug 24, frame and crate - YouTube
Sunday
Demo Aug 25, Assemble the battery pack and install into the Electric Motor Module frame - YouTube Demo Aug 25, Cover tools in electrical tape, torque battery posts - YouTube