Testing Batteries

[maccafan]

Ah I see..

Well charge output variation is to be expected..Depends on the charge state of the battery and the circuit inside the ego types regulate the charge current and voltage..

[VE Jason]

I should add that we use these testers prior to dispatch, not for returns.

I'm looking to get one sorted out that will take a bank of say 10 batteries at a time, to make things easier.

[maccafan]

I'll have a think about that and let you know..

[Batdragon (AKA Batty)]

I would be interested in seeing what your test rig is too. I am experimenting with trying to build this
www.instructables.com/id/Arduino-True-Battery-Capacity-Tester-Li-IonNiMH/?&sort=ACTIVE&limit=40&offset=40
But beefed up for the vaping world to give a proper battery test. Would also have to have an auto switching system to bush the battery button in and out to stop the long draw cutout happening, and that then would have to be worked into the equation of the battery time.

[VE Jason]

Just whilst it's on my mind then Macca....

The scenario is...

Someone gets a new cartomiser and attaches it to an eGo battery, battery flashes loads of times (their words not mine), customer removes the cartomiser and battery no longer works with any cartomiser ("just flashes loads of times").

The customer then proceeded to put the same cartomiser on a Riva Battery and an Echo Battery (I know, I know )

Same result...so 3 apparently dead batteries (should be on their way back to us)

Possible explanations?

[VE Jason]

You see, before you said that the Ego/Riva batteries had SC protection, I would have just written them off. Now look what you've started

[maccafan]

Jul 8, 2012 6:41:14 GMT VE Jason said:

Just whilst it's on my mind then Macca....

The scenario is...

Someone gets a new cartomiser and attaches it to an eGo battery, battery flashes loads of times (their words not mine), customer removes the cartomiser and battery no longer works with any cartomiser ("just flashes loads of times").

The customer then proceeded to put the same cartomiser on a Riva Battery and an Echo Battery (I know, I know )

Same result...so 3 apparently dead batteries (should be on their way back to us)

Possible explanations?

1. Most probable explanation:

Posi pin sticking out on carto or customer tightening carto too much or a combination and pushing the the posi pin on the battery inwards when screwed on, thereby damaging insulator causing a short by compressing it too much. It's only 0.5 mm thick. Insulator permanently damaged and short remains in place so battery will just flash every time because short condition still exists.

2. Another probable but less likely:

All batteries could be run down and need charging. Battery will flash then too when unable to supply load and shut down.

3. Another explanation least likely but not impossible:

Juice ingress has killed all circuit boards..Normally the battery will stay lit in these conditions with smoke pouring out of the battery button but you can never predict how a circuit behaves with liquid ingress.

Most likely 1.

But if you really do an engineering root cause analysis, it all points to the excessively soft silicone insulators that are being used in many batteries these days. They really are unfit for purpose causing sinking pins and eventually shorts. Older ego batteries I have seen used to use a hard rubber insulator which was really upto the job.

I have swapped all my silicone insulators for the harder rubber ones. You could tighten a carto on mine with a wrench and it would still work..

[VE Jason]

Thanks Macca, some good food for thought there.

One thing I will do is speak with the manufacturers and see if I can get the insulator changed on future orders.

All steps in the right direction

[maccafan]

I would make an educated guess that, that little insulator remains the biggest culprit in 80-90% of reported issues.

It is probably the cheapest component in the battery..There was a group buy being organised at vapeatron some time ago for 5000 pieces for $240.00 of the hard rubber kind..Dunno where from and what happened..