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Old 12-27-2015, 09:33 PM   #21 (permalink)
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Here's my layman's understanding after having 2 modules replaced. Whenever you hook up to a charger, the car's computer will shut down the charger as soon as any cell reaches full charge. If there are other cells that are lagging significantly behind that first "full" one in charge level, the computer may (no way of knowing for sure) go into "cell balancing mode" and keep the charger looking like it's active for hours or days. It is not drawing a lot of power ... it's only doing "slow/trickle charging" of the remaining cells so as not to overcharge the "best charged cell". There isn't a reliable way to force cell balancing to happen, but the best way to hopefully get the computer to go into balance mode is to drive the car down to 0 Stealth miles -- which is more likely to have the computer register the charge imbalance. But, it will only happen if the computer thinks it wants to do it. Leaving it on the charger for an extended period will do nothing, once you see the charger go off. It's done. If it stays "active" for more than 6 hours (on a 220V charger), it's probably balancing and you should leave it for a whole day (or more) until it clicks off.
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Old 12-27-2015, 11:50 PM   #22 (permalink)
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Originally Posted by shrowell View Post
Can you explain this "non-active balancing" a little further (or point me to somewhere on the forum where it has already been discussed)? How does keeping the car on the charger achieve this balancing? I assume the current drawn is minimal once the batteries reach full charge. What will keeping the charger active for a week (or so) actually achieve?

Given this advice is coming from you, PowerSource, I guess this is more than just theorizing.

A123 uses a very primitive way of balancing the pack, basically they are using a bleed resistor to limit current to "balanced" cells this strategy attempts to bring the out of balance cells to the same level. Essentially the pack is limited by the voltage of the weakest "paralleled" cell.

Issue here is it takes a very long time to balance the pack and this balance technique wastes a lot of energy in heat (which also requires extra energy for thermal management). There are many smarter ways to balance the pack. The one on the A123 pack is probably the cheapest way though.
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Old 12-28-2015, 12:27 AM   #23 (permalink)
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So... (and I'm thinking about saving $5k+ in battery module replacement here - sorry Pat), if I leave the charger plugged in and let the car's onboard charger take care of business, there's a chance that all the modules will eventually balance (to the lowest common denominator). Worth a go.

Thank you for the tip!


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Old 12-28-2015, 06:22 AM   #24 (permalink)
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@carnutdr I emailed you we will get it taken care of. Love the Gotti story, he's a mafia legend around here lol.
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