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Written by Flauschdompteur on 2024-09-15 at 18:42

PSA: There's a bunch of videos floating around how to repurpose elfbar vape batteries, and the newest one is horribly unsafe.

https://www.youtube.com/watch?v=ehp23hrrEHY

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Written by Flauschdompteur on 2024-09-15 at 18:44

First, the guy uses soldering irons directly on the batteries (2:22). This is extremely dangerous, applying heat to batteries can and will send them into thermal runaway.

Next, he's smart enough to use a "balance" board to equalize the cell charges. But it would be way better to deplete the batteries individually, and it would be even better to run each one through a grader to determine capacity - only use matching cells in a parallel pack.

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Written by Flauschdompteur on 2024-09-15 at 18:46

Then, his PCB sandwich does not leave any air holes. The innermost cells will end up with trapped heat during charge and discharge, and likely overheat. Never do that. And never run battery packs without a bunch of thermal sensors throughout a pack.

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Written by Flauschdompteur on 2024-09-15 at 18:48

At 7:57 I lost my mind entirely. Way too thin wires to sustain the 30+ amps the pack will go through at the 100 watts @ 3.3V.

But that's not all: he soldered the balancing wires while the pack PCB is energized! One uncautious movement that ends up shorting two intra-pack balance wires and the entire pack's voltage will short out through this.

What a horribly unsafe video. He's damn lucky to not have ended up with a serious battery fire in his home.

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Written by Flauschdompteur on 2024-09-15 at 18:51

Here's how to do things correctly:

  1. When disassembling vapes, wear gloves. You don't want to dose yourself with nicotine through skin contact.

  1. Always cut wires, only one wire at a time. Once a wire is cut, place a Wago lever connector on it, so that it cannot cause a short circuit. Do not solder on batteries, if you must use connectors, spot-weld them.

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Written by Flauschdompteur on 2024-09-15 at 18:53

  1. Always keep a bucket of fine sand nearby. When a battery looks like it's going off (it swells up, emits smoke or goes up in fire), dump the bucket of sand on it, leave the room and call the fire brigade. You are NOT equipped to deal with a lithium fire unless you're in a lab and trained in dealing with it.

  1. Always use plug connectors and wires rated for the amps you're going to pull through it. Always install a fuse in the pack PCB.

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Written by Flauschdompteur on 2024-09-15 at 18:55

  1. In designing a pack, keep thermals in mind. Ample holes for air/convection cooling, and liberally place thermal sensors in the pack so you can have the BMS cut off when the pack gets too hot.

  1. Select and match the cells you're putting in a pack. There's enough battery chargers that can do that for you.

Please don't go and create time bombs in your home.

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Toot

Written by Flauschdompteur on 2024-09-15 at 18:59

  1. Before manipulating li-ion cells, discharge them to at least 3.5V, better 3.3V (but no lower than 3V). Never work with charged batteries, only charge them when they are fully installed.

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