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Another concern is with the battery itself: I have six modules in series, connected by 1/8" thick copper bus bars wide enough to provide the same cross-section as 00 gauge wire. Nonetheless, when I draw too much torque (like driving in 50 mph headwind with the windshield up), my battery modules tend to get out of balance with a premature low-voltage alarm on the cells closer to the end connections.
That doesn't make sense to me: with all modules in series, they are all passing the same current... so how could it possibly matter whether a module is at the end of a string or the middle? This sounds like a thermal problem (due to the position of the module in the middle of the stack or the end), rather than an electrical problem (due to the position of the module in the middle of the series string at the end). Is there enough coolant flow, and is it balanced between the modules?
 
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