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Thread: Headway pack frustration, unsure of where to go.

              
   
   
  1. #1
    Senior Member mcf12's Avatar
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    Headway pack frustration, unsure of where to go.

    Alright,

    Been trying to keep a headway pack that I punished going. Had one bad cell with increased resistance in pack and rode while waiting for new cells to come it, even tho it got up to voltage on charge.

    Came home, couldn't get charge bc BMS saw that cell at zero, called a fault. Waited a few days to pull the pack and test each cell. Here's what we've got:

    0.279
    1.003
    0.989
    0.643
    1.088
    1.465
    1.195
    1.223
    1.153
    1.342
    1.494
    1.901
    1.378
    1.138
    1.22
    1.5
    0.902
    1.171
    0.923
    1.615
    1.562
    0.882
    0.98
    0.968
    1.502
    0.989
    0
    1.1156
    3.049
    1.228
    3.089
    1.38

    total 40.3666 (32s2p worth of 40152 headways)


    They haven't been charged since that last run, so surely many here are recoverable, but I'm now torn about how to really keep trying to salvage some of these vs scrapping it and starting over. Also interested in a 18650 pack build. Maybe a leaf or volt pack. I don't know.

    Questions:

    What would you do with this info?
    Would you patiently go through pack and rebuild? If so, how many of these do you think are shot vs not?
    Would you even think about a 18650 or other chemistry? The headways are cool, but I'm bumming that the 10c isn't really there.
    This is a 32s2p with 15ah 40152 headways. Might get a little more range and discharge capacity in a new config, anyway.

    Thoughts?

    Thanks, MC

  2. #2
    Status-free and luvin' it
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    You have 64 cells but gave 32 measurements?

    Low voltage cut-off is 2.0 volts, you're well below that on a good chunk of those cells. I don't have a ton of experience with headway (building a 192 cell pack right now) but if you've been nursing this pack I'd say those cells are toast or at least will not "revive" with any more TLC.
    Mike Pipes
    - Currently under analysis paralysis.

  3. #3
    Senior Member mcf12's Avatar
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    Those are the measures of the pairs, still in 2p

  4. #4
    Senior Member DRZ400's Avatar
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    Sorry to say, but you probably need to start over...even if "revived" they will certainly have diminished and varying capacities and be very difficult to keep balanced. You could cycle and sort them to see what you have?
    2003 Ninja 250EX, Agni #95R, 6:1 Gearing, 11 Leaf Modules.
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  5. #5
    I should be working! furyphoto's Avatar
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    Cycling these batteries individually (not in 2P) with an logging charger (like and icharger 206b or 208b) would give you a good idea of what the capacity is and if the cells are useful or toast. I'm not familiar with Headways, and how robust they are when it comes to draining them so low, but if the cells are sitting that low I think you are mostly out of luck.

    The only way to salvage any of these is going to be to charge and test them individually to figure out if any are still good.
    -Andrew

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  6. #6
    Senior Member mcf12's Avatar
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    thanks andrew. guess its time to break the whole pack down all the way and get them on the other charger see what we have.

  7. #7
    Senior Member mcf12's Avatar
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    Mocked up a leaf cell and it looks like I could get 11 cells stacked in the same space I've got my headways, and make the pack narrower than it is now. CG up an inch or two, nothing big. Pretty interesting, actually. Almost like it was made for them.

  8. #8
    Senior Member mcf12's Avatar
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  9. #9
    Senior Member DRZ400's Avatar
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    You would love the leaf cells...charge to 4.1 per cell and not below 3.6 (resting)...no need for BMS* *(based on my 44 cycles to date, all within .05v). The Leaf modules are not like Chinese cells (build, charge and ship), they are screened and matched to tight tolerances. Everybody gets A grade!
    Last edited by DRZ400; 30 August 2015 at 1520.
    2003 Ninja 250EX, Agni #95R, 6:1 Gearing, 11 Leaf Modules.
    Alltrax SPM72400, 400 amp Controller, all LED lighting
    2014 CRF450X Supermoto
    http://www.evalbum.com/1955
    http://www.evalbum.com/3337

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