[NSRCA-discussion] TP 1010 testing

Tue Mar 28 08:42:30 AKST 2006

Hi Chad,
I don't know the internals of the TP circuits, but if the data link from balancer to charger is a simple alarm, then
the balancer will have to produce the same alarm/output in either a real over-voltage, or a "can't keep up with a growing imbalance" condition. 
Either way, the circuit worked fine, to avoid problems.

The FMA just seamlessly slows the charge rate down, and resumes at high-rate, when the imbalance is taken care of.

Dean Pappas
Sr. Design Engineer
Kodeos Communications
111 Corporate Blvd.
South Plainfield, N.J. 07080
(908) 222-7817 phone
(908) 222-2392 fax
d.pappas at kodeos.com

-----Original Message-----
From: nsrca-discussion-bounces at lists.nsrca.org
[mailto:nsrca-discussion-bounces at lists.nsrca.org]On Behalf Of Chad
Northeast
Sent: Tuesday, March 28, 2006 12:28 PM
To: NSRCA Mailing List
Subject: Re: [NSRCA-discussion] TP 1010 testing

Hi Bob

The overvoltage seems to be quite common...I get it frequently...the packs are not going over voltage though...checked with my Fluke on recharge.  Seems to happen when the charger/balancer gets hot...I have seen it display over 6V for individual cells.

My charger goes into CV at 41V....but I have also had them terminate the charge early (41V)....unsure as to why.

Chad

----- Original Message -----
From: Robert Mairs <robertm at sssnet.com>
Date: Tuesday, March 28, 2006 8:51 am
Subject: [NSRCA-discussion] TP 1010 testing

> Got tired of building this last weekend, and decided to do some 
> testing of 
> the TP1010c charger.  Debated whether to post this, but some might 
> be 
> interested.
> 
> All tests were done with the 5s3p 6000 prolites that have 90-100 
> cycles on 
> them.
> 
> First off these packs haven't been touched since the end of 
> september, in 
> storage all winter.  So I proceeded to do a 1c charge, and then 
> discharged 
> with a cba to ck pack capacity.  They're holding up quite well 
> with about a 
> 4% drop in capacity as compared to new.  1c charge was quite 
> uneventful, 
> mostly getting accustomed to the charger.  I used both the 210 and 
> 205 
> balancers, both worked well with the system.  I did order 2 charge 
> systems, 
> but alas one charger had problems and has been sent back to 
> thunder power. 
> The push buttons seemed to lock up after a few seconds.  Only way 
> to get it 
> to unlock was to power it down.  Upon reactivation it would seem 
> alright, 
> but then the problem would reappear.  This was over several attempts.
> 
> I then decided to do a 10s charge after deep cycling the pack to 
> get a mah 
> reading.  Resting voltage of the pack 34.992.
> 
> A .029 spread over the 10 cells.  Close to the .03, but the 
> balancer said it 
> was ok to do normal charge.
> 
> Charger started the initial charge for about 4 min then ramped up 
> to 5amps 
> as it got close to 37volts.  At 40volts charger went into cv from 
> cc which 
> seemed a little early??  Balancer was working pretty hard by this 
> time.  Not 
> sure at what point it was, but the alarms and bells started going 
> off, and 
> the charger shut down stating overvoltage on cell 6.  Balancer was 
> pretty 
> hot and quite active.  Not sure why it couldn't keep up, but it 
> didn't.  Let 
> the pack continue to balance out, and restarted the charge which 
> took about 
> another 400mah before pack was fully charged.  Anyways, found out 
> the 
> overvoltage feature works!  Wisdom gained, if that big of a cell 
> spread, 
> balance it out first, but I was kind of surprised this happened.  
> First 
> because the balancer said ok, 2nd I thought the charger wouldn't 
> ramp up the 
> current until all cells were within specs, 3rd I didn't think the 
> balancer 
> would have any problem at 5amps which is only a .8c charge.
> 
> 
> 
> Redischarged the packs, taking out about 4500mah.  Pack voltage 
> this time 
> was at 37.26 with only .006 spread over the 10 cells.  Started the 
> same 10s 
> charge, this time uneventful til completion.  The balancer was 
> quite active, 
> but didn't heat up as the first charge did.  Total charge time was 
> 65 
> minutes and put in 4594mah.  Balancer was still active at end of 
> charge.
> cell voltage spread was .012 over the 10 cells, pack voltages were 
> 20.86 and 
> 20.84.  Not sure I like the 10s feature.
> 
> 
> 
> Decided to try a 1.5c charge on one of the 5s packs.
> 
> Resting voltage 18.68 with a .005 spread on the 5 cells.  Set to 
> 5cells 
> 9amps, fast charge.
> 
> 1st 1000mah at about 7min.
> 2nd 1000mah at about 13min.
> at 30min was at 3.86amps, voltage at 21v.  4290mah
> 31min   3.2amps, 4350mah
> 32min   2.78amps, 4390mah
> 33min   2.33amps, 4437mah
> 34min   2.13amps, 4474mah
> 35min   1.75amps, 4506mah
> 36min   1.58amps, 4533mah
> 36min 52sec  charge terminated at 4554mah
> 
> cv kicked in at 20.48volts
> 
> Ending voltage was 20.85 with a .006 spread over the 5 cells.  
> Noticed no 
> heat buildup in pack, or balancer.  Balancer showed little 
> activity through 
> out the charge.  Didn't work nearly as hard as the successful 10s 
> charge. 
> Used the 205v balancer on the 1.5c charge.
> 
> Also tried the storage discharge and charge which worked quite 
> well.  The 
> discharge came closer at 19.26 volts, can only discharge a 1amp.
> 
> Chargers quite easy to use.  I'm leaning towards the 1.5c charge 
> with 2 
> chargers.  It worked very well.  Will have to wait and see how 
> long it takes 
> to get my 2nd charger back.
> Anyways that's the way it went for me for those interested.
> 
> 
> 
> 
> 
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