Need help with XB-600 scooter - Blew up the batteries!

[eeraser]

What a depressing week-end! three months ago I got a 5th battery for my 1 month old XB-600 (upped the 48v to 60V) and everything was fine until Saturday. After a 3 mile ride on a new charge, the batteries were pretty much drained! Took them down to the local battery store and found the one I had added was bad. Left it with them for further testing and went home to install the 4 original batteries, plugged the original 48V charger and went to bed.

Went out 12 hours later to a hissing noise, a really hot garage and the smell, OH BOY!

Fortunately, I did not screw down the battery cover, popped it open and the tops of the batteries had expanded, spewing the batteries sweet nectar over my carpet and down onto the garage floor and a pretty intense heat, even after 4 hours of cooling. Not sure why they exploded like that. My first guess is that I installed one of the batteries backwards and I'll confirm that later, but I am 100% sure I had them correct and I double checked them before I plugged the charger in.

Now for the good news, I get to rebuild it...STRONGER, FASTER, SMARTER! How would you rebuild a scooter that just exploded? I think my first purchase is going to be 5 Lithium batteries. What else, or what advice can you offer? :-)

[wolfraven]

Good lithium batteries and a good charger...and much more power! I'm helping a friend from work overvolt a little electric quad toy he found...because he thinks it's too slow and will burn out...hehe...It's basically a stripped electric But more voltage + good lithium batteries and...maybe an updated controller? A real EV controller if you need to...because that'd rock, even though that adds to the cost...and I want one of those scooters...lol! Good luck, keep me posted!

[eeraser]

Any recommendations on where to find a good controller or a good supplier of parts? Not going to eBay for this!! :-)

I'll post some pics tomorrow of the aftermath!

[captainslug]

Relevant to your interests.
http://ecomodder.com/forum/showthrea...mods-5158.html

In a few weeks I will be upgrading to 72 volts, and replacing my 60 volt charger with an array of 12 volt chargers.

I've replaced all of my batteries once so far.

There's much more discussion of XB-600s on this forum
http://visforvoltage.org/forums/elec...00-xb600-xb700

[eeraser]

yeah, I posted there as well. I started pouring through the tons replies to all of the threads, but it isn't easy finding reviews and info on rebuilding.

[eeraser]

Here are the photos of my old, dead, exploded, ugly batteries. They were REALLY hot for several hours and since they expanded sideways as well, they are wedged in there pretty good!

Still haven't found a good battery supplier

[captainslug]

Mine is pretty naked now. I ditched the body panels a long time ago.

I'm having problems with my current charger overheating and overcharging my pack. The batteries in the middle of the pack have started to swell, so I've ordered a replacement charger.
My stock batteries only had issues with developing corroded terminals.

Originally Posted by eeraser

Still haven't found a good battery supplier

$38 each from Electric Vehicles USA, which I ordered my 5th battery as well as my first replacement set from.
Electric Vehicles USA, Inc

Or if you want an even better deal you can get a set of 4 for $140 shipped
RBC11 - APC Replacement Battery 12V 20AH (4) - eBay (item 310130075904 end time Apr-18-09 13:01:37 PDT)

I've received two sets from them already.

[eeraser]

I love that scooter, it looks like a cat that just got out of the bath tub!


I was thinking about getting away from SAL batteries and going to Li-Ion batteries?

[captainslug]

Originally Posted by eeraser

I was thinking about getting away from SLA batteries and going to Li-Ion batteries?

I'm of the opinion that it wouldn't be worth the expense. And for a vehicle this light going with a much lighter pack would actually make the handling worse. The frame itself weighs next to nothing.

Li-Ion packs have to be made custom or in low volume, and there are very few reputable people offering them.

eBay Store - PingBattery: 36V LiFePO4 Batteries, 48V 24V Battery, Electric Bike Scooter
has a very good reputation for making custom packs. Many many users at the Endless-Sphere.com forums have had him make custom packs for their electric bike conversions.

[eeraser]

great! Thanks for the advice, you have be SO HELPFUL!
I think I may take your advice and stick with SLA batteries....