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Discussion Starter · #1 ·
Aloha all. This weekend and next the batteries go in the Yaris.

1: I have 23 used 160ah TS that are a bit swelled. Can I unswell them bit by bit or shud I leave them alone and not let them swell any more? I am making the battery holders with allthread rods on top and bottom of the battery box. As I install the batteries I will snug up the allthread bolts to XX ft-lbs and periodically check and retighten and hopefully the bulge will flatten over time?? Comments ....will it ruin if I snug too much?

2: I will have a total of 46 160ah TS batteries. What is the best placement? ie put as many in the front and the rest in the back? Seem like this is the way to go, but is it better to put slightly more in the rear (it is a 2007 Yaris 3 dr hatchback), and less in the front?

comments?
thanks
francis
 

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I would suggest as many as will fit up front, not to exceed the stock front axle weight by more than about 100 pounds (FWD cars don't need to get more nose heavy.) The rest should go to the rear while not allowing the rear axle weight to exceed the front axle weight (FWD car suspensions are not set up to be tail heavy.) Likely that was a long way of saying fill the front then put the rest in back.

You can re-compress the cells, TS even shows pictures of such clamps. I wouldn't get carried away, I've heard just applying gentle force will flatten them over time if you don't overcharge. Swelling suggests the internal resistance is higher than new, I don't know if flattening the cells back out will take it back down.

46 cells will make a nice 144 volt pack. I've been slipping Lithium into the EV buggy this week too.
 

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Discussion Starter · #3 ·
Aloha, I got some calb 180ah batteries to match as closely as possible to my 160ah TS in size and amperage. Here are the specs that came with the 28 cells. Are #80 and #98 bad? Francis
 

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Aloha, I got some calb 180ah batteries to match as closely as possible to my 160ah TS in size and amperage. Here are the specs that came with the 28 cells. Are #80 and #98 bad? Francis
They're not bad, but will lose energy to heating more so than the other cells over time at a fairly slow rate, though depending on your amperate draw/charging. If you don't use a BMS, I would check on those two cells at least once a month and initially daily or weekly.
 

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No, but I would prefer to avoid using them in your pack if not required. If you are using some type of battery bridge type monitoring system they should be on opposite halves of the pack. In fact, that data would let you set up your pack with well matched internal resistance on each half for that type of monitoring.
 

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Discussion Starter · #6 · (Edited)
No, but I would prefer to avoid using them in your pack if not required. If you are using some type of battery bridge type monitoring system they should be on opposite halves of the pack. In fact, that data would let you set up your pack with well matched internal resistance on each half for that type of monitoring.
Lets see if I can exchange the 2 ....

Yes I have my total pack of 46 cells divided into 23x 160ah TS and 23x180 Calb. I will be watching the TS 160's as they will be the weakest with only 160ah, so they will be the weak links. I will charge the 160 and 180 (195ah?) separately.

Francis
 

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The increase in internal resistance will result in a voltage drop of 1/8 volt at 500 amps. If you are already doing a mixed pack of older TS cells and new CALB cells I suspect the increase in internal resistance will be the least of your issues.

Older TS cells certainly have more internal resistance than the new CALB cells. Newer TS cells, the Yttrium ones, seem to have pretty low internal resistance.
 

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Lets see if I can exchange the 2 ....

Yes I have my total pack of 46 cells divided into 23x 160ah TS and 23x180 Calb. I will be watching the TS 160's as they will be the weakest with only 160ah, so they will be the weak links. I will charge the 160 and 180 (195ah?) separately.

Francis
Why? This will be of absolutely no benefit to you.
 
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