mirror of
https://expo.survex.com/repositories/expoweb/.git/
synced 2024-11-21 23:01:55 +00:00
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">
|
||
<html>
|
||
<head>
|
||
<meta http-equiv="Content-Type" content="text/html; charset=utf8" />
|
||
<title>CUCC Expedition Handbook: Drill Battery Charging</title>
|
||
<link rel="stylesheet" type="text/css" href="../css/main2.css" />
|
||
|
||
|
||
|
||
</head>
|
||
<body>
|
||
<h2 id="tophead">CUCC Expedition Handbook</h2>
|
||
<h1>Makita Drill Battery Charging</h1>
|
||
<p>[None of this applies to the Bosch drills and their battery packs.]
|
||
|
||
<h2>Instructions for charging</h3>
|
||
<p>Please check with a battery nerd whether this is still up to date. It was valid on Expo 2022.
|
||
|
||
<p>We have 2 types of batteries:
|
||
<ol>
|
||
<li>Blue taped, which are original Makita</li>
|
||
<li>Green taped, which are modified by us</li>
|
||
</ol>
|
||
</p>
|
||
|
||
<p>Batteries need to be charged on compatible chargers.</p>
|
||
|
||
<p>We have 3 types of charger:
|
||
<ol>
|
||
<li>Standard Makita, both 12V at top camp and 240V at base camp.</li>
|
||
<li>´Triple' balance charger made of 3 makita chargers munged together.</li>
|
||
<li>Accucell6 (or older Pro-Power Prodigy) 'RC' chargers plus adaptor to connect to batteries</li>
|
||
</ol>
|
||
</p>
|
||
|
||
<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>
|
||
|
||
<p>2 will charge only Green-taped modified batts. Charge Green-taped batts on this.</p>
|
||
|
||
<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>
|
||
|
||
|
||
<h3>Using Balance charger</h3>
|
||
|
||
<p>This is the set of 3 (2 half-width) chargers made from old green/turquoise Makita chargers.
|
||
They have a set of 4 LEDs. (The full-width one only has 1 LED in 2018). Charges at 40W.</p>
|
||
|
||
<ol>
|
||
<li>Make sure charger is powered (flashing green LEDs).</li>
|
||
|
||
<li>Plug batt into charger. After a few seconds it should start charging.</li>
|
||
|
||
<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>
|
||
|
||
<li>Eventually it should show '100%' (steady green LEDs). (1hr 50 max possible charge time). You are done.</li>
|
||
</ol>
|
||
|
||
|
||
|
||
<h3 id="RCcharge">Accucell 6 RC charger</h3>
|
||
|
||
<p>This is the black all-purpose charger with LCD display. Charges at up to 50W</p>
|
||
|
||
<p>The Yellow Propeak chargers do the same job, and instructions are
|
||
similar, but have no fan, no backlit display, and if pack is low
|
||
voltage will charge at C/10 (10% of normal) until voltage rises
|
||
sufficiently. Charges at up to 50W.</p>
|
||
|
||
<ol>
|
||
<li>Make sure charger is powered (display lit up)</li>
|
||
|
||
<li>Connect charger to battery (either hardboard adaptor or empty
|
||
Makita green/turquoise base adaptor). Check polarity is correct with hardboard
|
||
adaptor.</li>
|
||
|
||
|
||
<li>Check display says 'Lion' or 'Lipo' and '14.4V' and '3A' and 'CHARGE'. Hold
|
||
down "<b>Enter, Start Stop</b>" button
|
||
(the one at the <b>right-hand end</b>, the <b>4th one from the left</b>) . It will do a battery check.
|
||
<p style="
|
||
color:darkblue;
|
||
background-color:lightblue;
|
||
display: block;
|
||
margin-top: 1em;
|
||
margin-bottom: 1em;
|
||
margin-left: 10px;
|
||
margin-right: 65%;
|
||
border: 2px solid blue;
|
||
padding:2%;
|
||
font:22px/30px monospace;">
|
||
LiIo CHARGE<br>
|
||
C=3300mAh 14.4Vp
|
||
</p></li>
|
||
|
||
<li>If it shows '<b>4</b>' as the number of cells, then press
|
||
"<b>start/enter</b>" again. Charging will start (fan comes on, display
|
||
changes). If it shows anything else like '<b>polarity reversed</b>' or
|
||
'<b>connection break</b>' then fix the connection to the battery. If
|
||
it shows '<b>3</b>' as number of cells it may be knackered, but more
|
||
likely is just overdischarged, and thus can be coaxed back into
|
||
action. Let it charge is if 3-cells for a minute or so, then
|
||
restart. It should now register 4 cells.</li>
|
||
|
||
<li>Once it beeps and says 'FULL' (flashing) then you are done (should
|
||
be less than 2 hours). Display shows number of mAh put in in
|
||
bottom right. Should be a number like 250 for each hole drilled
|
||
(between 50 and 2900 depending how discharged it was).</li>
|
||
|
||
</ol>
|
||
|
||
<h2>Background knowledge about drills and batteries</h2>
|
||
<p>This information will not go out of date.
|
||
<h3>Drills - read this!</h3>
|
||
<p>Note that the drills have no battery-voltage monitoring at all, and the
|
||
monitoring circuit in the battery is bypassed when connected to the drill. Thus the drill can easily be used to over-discharge a
|
||
battery, so please <b>stop drilling when it gets slow</b> and put on a new
|
||
battery, unless it's an emergency. Drilling with an excessively-sagged
|
||
voltage <b>will</b> knacker the weakest cell-pair. If your battery
|
||
does get to this state, try to charge it up as soon as possible. Cells
|
||
must not be left at <2V for any length of time as they rapidly
|
||
(hours/days?) degrade to useless in this state (and that pair will
|
||
need replacing - which means reassembling it back in Cambridge and welding in a new cell pair).</p>
|
||
|
||
<h3>Makita charging protocol issues</h3>
|
||
<figure>
|
||
<img src="i/makita2.jpg">
|
||
<figcaption>
|
||
<em>An unmodified Makita mains charger</em>
|
||
</figcaption>
|
||
</figure>
|
||
<p>Makita have put very 'conservative' software in the batteries (as bought) which
|
||
will stop them working on an as-bought, unmodified Makita charger, even when they are in
|
||
fact fine. The monitoring board in the batteries is powered from the 1st cell pair so
|
||
that pair tends to get discharged more than the others when left
|
||
sitting for the 11 months of not-expo. If an unbalanced (or
|
||
over-disharged, or too-hot) pack is inserted into the Makita charger
|
||
the charger and battery will do serial-comms negotiation, the charger
|
||
will refuse to charge the battery and <em>the battery will remember</em> this.
|
||
If you try this 3 times, the battery will mark itself bad and will
|
||
never charge again on a Makita charger. Only a replacement circuit
|
||
board in the battery can fix this (or new software if we knew how to nobble it).</p>
|
||
|
||
<p>Such batteries are normally still fine and charge on a sensible (RC
|
||
- Radio Control, because RC people are the main market for these
|
||
chargers) charger, possible after a "balance charge" to get the cells in
|
||
the pack in sync again. Expo has a couple of chargers capable of doing a "balance charge" (Black Accucell6 and older Yellow Pro-power
|
||
Prodigy II). Unfortunataly Makita don't build the 14.4V packs with
|
||
the necessary connections to the cells, so the circuit board in the battery has to be replaced to
|
||
make this work easily for expo. For 2018 this was done for 7 of our
|
||
packs, and 3 automatic balance chargers were built by Wookey.</p>
|
||
|
||
|
||
Further explanation: the charger uses a different pair of electrical connections from those used by the drill - that's why there are
|
||
not just two electrical connectors in the charger - to accommodate those extra connections.
|
||
<figure>
|
||
<img src="i/makita-panel2.jpg" width=45%>
|
||
<figcaption>
|
||
<em>A close-up of the control panel of an unmodified Makita mains charger</em>
|
||
</figcaption>
|
||
</figure>
|
||
|
||
<h3>Types of charger</h3>
|
||
<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:
|
||
<ul>
|
||
<li>Makita green/turquoise plastic as-bought mains-powered charger - only at base camp.
|
||
<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.
|
||
<li>Balance charger - This is the set of 3 (2 half-width) chargers made from old green Makita chargers.
|
||
They have a set of 4 LEDs. (The full-width one only has 1 LED in 2018).
|
||
<li>RC charger - a black all-purpose charger with blue LCD display.
|
||
</ul>
|
||
|
||
<h3>Makita batteries</h3>
|
||
<p>New for 2018 is varying battery capacity. We have 3Ah, 4Ah and 5Ah
|
||
packs. Bigger packs will take longer to charge from empty. The
|
||
capacity is on the cell label next to the yellow connector.</p>
|
||
|
||
<p>Each pack has a sliding indicator on the side. This is entirely
|
||
manual, but is very useful for indicating when a pack is known to be
|
||
charged, flat, or partly discharged. Slide the slider to show green
|
||
for full, red for flat, half and half for 'partly used'.</p>
|
||
|
||
<h3>Makita batteries: blue and green taped</h3>
|
||
|
||
<p>If a battery has green insulation tape on it it has been
|
||
modified by us and <b>will not charge</b> on an unmodified as-bought Makita charger.
|
||
<ul>
|
||
<li>Green-taped batteries must be charged on the triple balance charger (or RC chargers).
|
||
<li>Blue-taped (standard, as-bought) batteries will not charge on the balance chargers, so must
|
||
be charged on the Makita charger (or RC charger).
|
||
</ul>
|
||
All batteries will
|
||
charge on the RC chargers, but not as fast as on the as-bought (mains power only) Makita
|
||
charger. Go to <a href="#RCcharge">RC charger</a>.</li>
|
||
|
||
<h3>Can I tell if a battery is already charged?</h3>
|
||
|
||
<p>Simplest is try to charge it again and find that it says it is done
|
||
in a couple of minutes (Up to 4 mins on the balance chargers). This
|
||
may 'waste a life' on batteries that still work on the Makita
|
||
charger. Checking it on the RC charger will not waste a life. It will
|
||
quickly rise to 16.4V, and the current drop to 0.1A or so. That
|
||
indicates a full pack. It will tell you so after a while (1-5
|
||
mins).</p>
|
||
|
||
|
||
<h3>What sort of batteries are they</h3>
|
||
|
||
<p>The drill batts are 4S2P 14.4V lithium ion packs (8 18650 cells: 4 in
|
||
series, each being a parallel pair). This means that they are charged
|
||
as 4-cell packs, to 4.1V per cell-pair. They can be charged at up to
|
||
3A rate. Battery 1 has connector wired as balance connector. No other
|
||
packs have this yet (2017). The official Makita packs use Sony SE
|
||
US18650VT (1.5Ah, 20A high-drain) cells, and we have a few with with Samsung
|
||
INR18650-13Q (1.3Ah high-drain cells). All give a reliable 2.3-2.6Ah
|
||
capacity in practice, even after 9 years expo useage.</p>
|
||
|
||
<p>At end 2017 we bought two 4Ah packs. The non-makita one uses LG
|
||
DAHD21865 cells (2Ah, 25A). I can't read the Makita cell type without
|
||
unwelding the pack. For 2018 we made 3 new 5Ah packs from Samsung 25R
|
||
cells (2.5Ah, 20A) (Sponsored by uk18650.com).</p>
|
||
|
||
<p>The drill discharges at 26A current draw when drilling (~400W), so
|
||
that's 13A per cell in a 2P configuration.</p>
|
||
|
||
<h3>Using Makita mains charger</h3>
|
||
|
||
<p>This is the green/turquoise charger with 3 LEDs, and diagrammatic charging info on RH side. Charges at up to 100W.</p>
|
||
|
||
<ol>
|
||
<li>Make sure charger is powered (flashing green LED).</li>
|
||
|
||
<li>Slide battery into Makita charger. It should start charging.</li>
|
||
|
||
<li>Look at the LEDs for status - the legend is printed on the charger.
|
||
If it flashes 'broken battery' (flashing red and gren LED) at you
|
||
after a few seconds, use the yellow (Pro-Peak Prodigy II) charger instead.</li>
|
||
|
||
<li>Eventually it should show '100%' (steady green LED) (in about 1
|
||
hour max). You are done.</li>
|
||
</ol>
|
||
|
||
<h2>Everything below here may be out of date due to breakages</h2>
|
||
|
||
Pro-peak Chargers (~2010-2019)
|
||
<h3>Short Instructions</h3>
|
||
<p>First insert the battery.
|
||
<p><img src="i/propeak.jpg" align="right" hspace="10px"/>
|
||
<p>
|
||
Check that screen looks like this: Displaying <br>
|
||
|
||
<p style="
|
||
color:darkblue;
|
||
background-color:lightblue;
|
||
display: block;
|
||
margin-top: 1em;
|
||
margin-bottom: 1em;
|
||
margin-left: 10px;
|
||
margin-right: 65%;
|
||
border: 2px solid blue;
|
||
padding:2%;
|
||
font:22px/30px monospace;">
|
||
LiIo CHARGE<br>
|
||
C=3300mAh 14.4Vp
|
||
</p>
|
||
<p>If this is not the case then move to <a href="#long">the long instructions</a>.
|
||
<br><br>
|
||
<p>If it is showing <em>exactly</em> as shown above, hold down the "<b>Enter, Start Stop</b>" button
|
||
(the one at the <b>right-hand end</b>, the <b>4th one from the left</b>) for two seconds.
|
||
The screen will display "battery check" and then start charging.
|
||
<p>The screen will then look something like below
|
||
(but with different numbers) when charging:
|
||
<p style="
|
||
color:darkblue;
|
||
background-color:lightblue;
|
||
display: block;
|
||
margin-top: 1em;
|
||
margin-bottom: 1em;
|
||
margin-left: 10px;
|
||
margin-right: 65%;
|
||
border: 2px solid blue;
|
||
padding:2%;
|
||
font:22px/30px monospace;">
|
||
CHG 0.04 00002<br>
|
||
LI+3.26A 15.331V
|
||
</p>
|
||
|
||
<p>If this is not the case then move to <a href="#long">the long instructions</a>.
|
||
|
||
<h3 id="long">Long Instructions</h3>
|
||
<p>First insert the battery.
|
||
<p>If the charging screen is not displaying the settings shown above then the correct <b>charging settings</b> need to be selected.
|
||
You can do this as follows.
|
||
<ul>
|
||
<li>First using the "<b>Batt Type</b>" button (First from the left) cycle through the settings until <b>Li-ion</b> is displayed.
|
||
<li>Next using the "<b>Enter, Start Stop</b>" button (4th from the left) select the "<b>C=</b>" field
|
||
(this will flash when selected) then increase or decrease the current using the "<b>Inc</b>" or "<b>Dec</b>" buttons
|
||
(2nd and 3rd from the left) until <b>3300mAh</b> is displayed.
|
||
<li> Using the "<b>Enter, Start Stop</b>" button cycle to the next "<b>Vp</b>" field. Again use the "<b>Inc</b>" or
|
||
"<b>Dec</b>" buttons until <b>14.4Vp</b> is displayed.
|
||
</ul>
|
||
<p>Now hold down the "<b>Enter, Start Stop</b>" button for 2 seconds until "<b>Battery Check</b>" is displayed
|
||
and the screen looks similar to below, but with different numbers:
|
||
|
||
<p style="
|
||
color:darkblue;
|
||
background-color:lightblue;
|
||
display: block;
|
||
margin-top: 1em;
|
||
margin-bottom: 1em;
|
||
margin-left: 10px;
|
||
margin-right: 65%;
|
||
border: 2px solid blue;
|
||
padding:2%;
|
||
font:22px/30px monospace;">
|
||
CHG 0.04 00002<br>
|
||
LI+3.26A 15.331V
|
||
</p>
|
||
|
||
|
||
<hr />
|
||
|
||
|
||
</body>
|
||
</html>
|
||
|