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326 lines
13 KiB
HTML
326 lines
13 KiB
HTML
<!DOCTYPE html PUBLIC "-//W3C//DTD XHTML 1.0 Strict//EN" "http://www.w3.org/TR/xhtml1/DTD/xhtml1-strict.dtd">
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<html>
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<head>
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<meta http-equiv="Content-Type" content="text/html; charset=utf8" />
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<title>CUCC Expedition Handbook: Drill Battery Charging</title>
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<link rel="stylesheet" type="text/css" href=/css/main2.css />
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</head>
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<body>
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<h2 id="tophead">CUCC Expedition Handbook</h2>
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<h1>Makita Drill Battery Charging</h1>
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<p>[None of this applies to the Bosch drills and their battery packs.]
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<h2>Instructions for charging</h3>
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<p>Please check with a battery nerd whether this is still up to date. It was valid on Expo 2022.
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<p>We have 2 types of batteries:
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<ol>
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<li>Blue taped, which are original Makita</li>
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<li>Green taped, which are modified by us</li>
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</ol>
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</p>
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<p>Batteries need to be charged on compatible chargers.</p>
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<p>We have 3 types of charger:
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<ol>
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<li>Standard Makita, both 12V at top camp and 240V at base camp.</li>
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<li>´Triple' balance charger made of 3 makita chargers munged together.</li>
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<li>Accucell6 (or older Pro-Power Prodigy) 'RC' chargers plus adaptor to connect to batteries</li>
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</ol>
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</p>
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<p>1 will charge <em>only</em> Blue-taped standard batts. Do <b>NOT</b> just try again more than once if you get an error. 3 tries can make a battery permanently unusable. This is the normal charger to use for Blue taped batts.</p>
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<p>2 will charge only Green-taped modified batts. Charge Green-taped batts on this.</p>
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<p>3 can charge all the batteries, but needs to be set up correctly. See below. It is normally used for diagnostics and recovering over-discharged packs which will not charge on the normal chargers.</p>
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<h3>Using Balance charger</h3>
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<p>This is the set of 3 (2 half-width) chargers made from old green/turquoise Makita chargers.
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They have a set of 4 LEDs. (The full-width one only has 1 LED in 2018). Charges at 40W.</p>
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<ol>
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<li>Make sure charger is powered (flashing green LEDs).</li>
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<li>Plug batt into charger. After a few seconds it should start charging.</li>
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<li>Look at the LEDs for status - the legend is printed on the RH end charger. Steady red for bulk charging to 80%. Steady orange for last 20% charging. Steady green for finished. If it flashes red and beeps (repeated 5 times) something is wrong - see table. If you get an 'undervoltage' reading, use an RC charger instead to get the charging started.</li>
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<li>Eventually it should show '100%' (steady green LEDs). (1hr 50 max possible charge time). You are done.</li>
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</ol>
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<h3 id="RCcharge">Accucell 6 RC charger</h3>
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<p>This is the black all-purpose charger with LCD display. Charges at up to 50W</p>
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<p>The Yellow Propeak chargers do the same job, and instructions are
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similar, but have no fan, no backlit display, and if pack is low
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voltage will charge at C/10 (10% of normal) until voltage rises
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sufficiently. Charges at up to 50W.</p>
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<ol>
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<li>Make sure charger is powered (display lit up)</li>
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<li>Connect charger to battery (either hardboard adaptor or empty
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Makita green/turquoise base adaptor). Check polarity is correct with hardboard
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adaptor.</li>
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<li>Check display says 'Lion' or 'Lipo' and '14.4V' and '3A' and 'CHARGE'. Hold
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down "<b>Enter, Start Stop</b>" button
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(the one at the <b>right-hand end</b>, the <b>4th one from the left</b>) . It will do a battery check.
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<p style="
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color:darkblue;
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background-color:lightblue;
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display: block;
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margin-top: 1em;
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margin-bottom: 1em;
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margin-left: 10px;
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margin-right: 65%;
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border: 2px solid blue;
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padding:2%;
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font:22px/30px monospace;">
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LiIo CHARGE<br>
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C=3300mAh 14.4Vp
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</p></li>
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<li>If it shows '<b>4</b>' as the number of cells, then press
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"<b>start/enter</b>" again. Charging will start (fan comes on, display
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changes). If it shows anything else like '<b>polarity reversed</b>' or
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'<b>connection break</b>' then fix the connection to the battery. If
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it shows '<b>3</b>' as number of cells it may be knackered, but more
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likely is just overdischarged, and thus can be coaxed back into
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action. Let it charge is if 3-cells for a minute or so, then
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restart. It should now register 4 cells.</li>
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<li>Once it beeps and says 'FULL' (flashing) then you are done (should
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be less than 2 hours). Display shows number of mAh put in in
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bottom right. Should be a number like 250 for each hole drilled
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(between 50 and 2900 depending how discharged it was).</li>
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</ol>
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<h2>Background knowledge about drills and batteries</h2>
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<p>This information will not go out of date.
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<h3>Drills - read this!</h3>
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<p>Note that the drills have no battery-voltage monitoring at all, and the
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monitoring circuit in the battery is bypassed when connected to the drill. Thus the drill can easily be used to over-discharge a
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battery, so please <b>stop drilling when it gets slow</b> and put on a new
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battery, unless it's an emergency. Drilling with an excessively-sagged
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voltage <b>will</b> knacker the weakest cell-pair. If your battery
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does get to this state, try to charge it up as soon as possible. Cells
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must not be left at <2V for any length of time as they rapidly
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(hours/days?) degrade to useless in this state (and that pair will
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need replacing - which means reassembling it back in Cambridge and welding in a new cell pair).</p>
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<h3>Makita charging protocol issues</h3>
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<figure>
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<img src="i/makita2.jpg">
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<figcaption>
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<em>An unmodified Makita mains charger</em>
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</figcaption>
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</figure>
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<p>Makita have put very 'conservative' software in the batteries (as bought) which
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will stop them working on an as-bought, unmodified Makita charger, even when they are in
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fact fine. The monitoring board in the batteries is powered from the 1st cell pair so
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that pair tends to get discharged more than the others when left
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sitting for the 11 months of not-expo. If an unbalanced (or
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over-disharged, or too-hot) pack is inserted into the Makita charger
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the charger and battery will do serial-comms negotiation, the charger
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will refuse to charge the battery and <em>the battery will remember</em> this.
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If you try this 3 times, the battery will mark itself bad and will
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never charge again on a Makita charger. Only a replacement circuit
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board in the battery can fix this (or new software if we knew how to nobble it).</p>
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<p>Such batteries are normally still fine and charge on a sensible (RC
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- Radio Control, because RC people are the main market for these
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chargers) charger, possible after a "balance charge" to get the cells in
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the pack in sync again. Expo has a couple of chargers capable of doing a "balance charge" (Black Accucell6 and older Yellow Pro-power
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Prodigy II). Unfortunataly Makita don't build the 14.4V packs with
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the necessary connections to the cells, so the circuit board in the battery has to be replaced to
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make this work easily for expo. For 2018 this was done for 7 of our
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packs, and 3 automatic balance chargers were built by Wookey.</p>
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Further explanation: the charger uses a different pair of electrical connections from those used by the drill - that's why there are
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not just two electrical connectors in the charger - to accommodate those extra connections.
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<figure>
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<img src="i/makita-panel2.jpg" width=45%>
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<figcaption>
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<em>A close-up of the control panel of an unmodified Makita mains charger</em>
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</figcaption>
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</figure>
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<h3>Types of charger</h3>
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<p>We have these types of charger; the non-mains chargers are all at top camp and can run all night using the car batteries:
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<ul>
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<li>Makita green/turquoise plastic as-bought mains-powered charger - only at base camp.
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<li>ProPeak/Makita charger - a yellow ProPeak box with a blue LCD display connected to the green battery slide connector cut out from a Makita charger.
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<li>Balance charger - This is the set of 3 (2 half-width) chargers made from old green Makita chargers.
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They have a set of 4 LEDs. (The full-width one only has 1 LED in 2018).
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<li>RC charger - a black all-purpose charger with blue LCD display.
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</ul>
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<h3>Makita batteries</h3>
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<p>New for 2018 is varying battery capacity. We have 3Ah, 4Ah and 5Ah
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packs. Bigger packs will take longer to charge from empty. The
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capacity is on the cell label next to the yellow connector.</p>
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<p>Each pack has a sliding indicator on the side. This is entirely
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manual, but is very useful for indicating when a pack is known to be
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charged, flat, or partly discharged. Slide the slider to show green
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for full, red for flat, half and half for 'partly used'.</p>
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<h3>Makita batteries: blue and green taped</h3>
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<p>If a battery has green insulation tape on it it has been
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modified by us and <b>will not charge</b> on an unmodified as-bought Makita charger.
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<ul>
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<li>Green-taped batteries must be charged on the triple balance charger (or RC chargers).
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<li>Blue-taped (standard, as-bought) batteries will not charge on the balance chargers, so must
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be charged on the Makita charger (or RC charger).
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</ul>
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All batteries will
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charge on the RC chargers, but not as fast as on the as-bought (mains power only) Makita
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charger. Go to <a href="#RCcharge">RC charger</a>.</li>
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<h3>Can I tell if a battery is already charged?</h3>
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<p>Simplest is try to charge it again and find that it says it is done
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in a couple of minutes (Up to 4 mins on the balance chargers). This
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may 'waste a life' on batteries that still work on the Makita
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charger. Checking it on the RC charger will not waste a life. It will
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quickly rise to 16.4V, and the current drop to 0.1A or so. That
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indicates a full pack. It will tell you so after a while (1-5
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mins).</p>
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<h3>What sort of batteries are they</h3>
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<p>The drill batts are 4S2P 14.4V lithium ion packs (8 18650 cells: 4 in
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series, each being a parallel pair). This means that they are charged
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as 4-cell packs, to 4.1V per cell-pair. They can be charged at up to
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3A rate. Battery 1 has connector wired as balance connector. No other
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packs have this yet (2017). The official Makita packs use Sony SE
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US18650VT (1.5Ah, 20A high-drain) cells, and we have a few with with Samsung
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INR18650-13Q (1.3Ah high-drain cells). All give a reliable 2.3-2.6Ah
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capacity in practice, even after 9 years expo useage.</p>
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<p>At end 2017 we bought two 4Ah packs. The non-makita one uses LG
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DAHD21865 cells (2Ah, 25A). I can't read the Makita cell type without
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unwelding the pack. For 2018 we made 3 new 5Ah packs from Samsung 25R
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cells (2.5Ah, 20A) (Sponsored by uk18650.com).</p>
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<p>The drill discharges at 26A current draw when drilling (~400W), so
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that's 13A per cell in a 2P configuration.</p>
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<h3>Using Makita mains charger</h3>
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<p>This is the green/turquoise charger with 3 LEDs, and diagrammatic charging info on RH side. Charges at up to 100W.</p>
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<ol>
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<li>Make sure charger is powered (flashing green LED).</li>
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<li>Slide battery into Makita charger. It should start charging.</li>
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<li>Look at the LEDs for status - the legend is printed on the charger.
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If it flashes 'broken battery' (flashing red and gren LED) at you
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after a few seconds, use the yellow (Pro-Peak Prodigy II) charger instead.</li>
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<li>Eventually it should show '100%' (steady green LED) (in about 1
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hour max). You are done.</li>
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</ol>
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<h2>Everything below here may be out of date due to breakages</h2>
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Pro-peak Chargers (~2010-2019)
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<h3>Short Instructions</h3>
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<p>First insert the battery.
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<p><img src="i/propeak.jpg" align="right" hspace="10px"/>
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<p>
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Check that screen looks like this: Displaying <br>
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<p style="
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color:darkblue;
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background-color:lightblue;
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display: block;
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margin-top: 1em;
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margin-bottom: 1em;
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margin-left: 10px;
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margin-right: 65%;
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border: 2px solid blue;
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padding:2%;
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font:22px/30px monospace;">
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LiIo CHARGE<br>
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C=3300mAh 14.4Vp
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</p>
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<p>If this is not the case then move to <a href="#long">the long instructions</a>.
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<br><br>
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<p>If it is showing <em>exactly</em> as shown above, hold down the "<b>Enter, Start Stop</b>" button
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(the one at the <b>right-hand end</b>, the <b>4th one from the left</b>) for two seconds.
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The screen will display "battery check" and then start charging.
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<p>The screen will then look something like below
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(but with different numbers) when charging:
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<p style="
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color:darkblue;
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background-color:lightblue;
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display: block;
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margin-top: 1em;
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margin-bottom: 1em;
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margin-left: 10px;
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margin-right: 65%;
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border: 2px solid blue;
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padding:2%;
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font:22px/30px monospace;">
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CHG 0.04 00002<br>
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LI+3.26A 15.331V
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</p>
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<p>If this is not the case then move to <a href="#long">the long instructions</a>.
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<h3 id="long">Long Instructions</h3>
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<p>First insert the battery.
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<p>If the charging screen is not displaying the settings shown above then the correct <b>charging settings</b> need to be selected.
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You can do this as follows.
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<ul>
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<li>First using the "<b>Batt Type</b>" button (First from the left) cycle through the settings until <b>Li-ion</b> is displayed.
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<li>Next using the "<b>Enter, Start Stop</b>" button (4th from the left) select the "<b>C=</b>" field
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(this will flash when selected) then increase or decrease the current using the "<b>Inc</b>" or "<b>Dec</b>" buttons
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(2nd and 3rd from the left) until <b>3300mAh</b> is displayed.
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<li> Using the "<b>Enter, Start Stop</b>" button cycle to the next "<b>Vp</b>" field. Again use the "<b>Inc</b>" or
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"<b>Dec</b>" buttons until <b>14.4Vp</b> is displayed.
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</ul>
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<p>Now hold down the "<b>Enter, Start Stop</b>" button for 2 seconds until "<b>Battery Check</b>" is displayed
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and the screen looks similar to below, but with different numbers:
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<p style="
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color:darkblue;
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background-color:lightblue;
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display: block;
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margin-top: 1em;
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margin-bottom: 1em;
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margin-left: 10px;
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margin-right: 65%;
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border: 2px solid blue;
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padding:2%;
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font:22px/30px monospace;">
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CHG 0.04 00002<br>
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LI+3.26A 15.331V
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</p>
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<hr />
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</body>
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</html>
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