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Bulging BYD packs

Solar_Mann

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Nov 18, 2019
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Received 5 of the byd packs from batteryhookup. Several of them are pretty heavily bulging but one of them has actually bulged some far is has broken the plastic end caps of the case. I emailed them, they’re only reply was feel free to ship it back. It seems pretty ridiculous they’d even ship one with a broken case, no where in there as does it say anything about damage, only decreased capacity.
 

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I just replied to there email, in there first reply they made no effort other than a refund if I pay to ship it back. Hopefully we can work something out, I’ve bought from them in the past and been happy but this seems like poor business to ship batteries that show clear signs of damage.
 
It's possible that the battery was damaged in shipping, and the bulge was just overlooked. Hopefully they make it right.
 
WOW return shipping on those beasts would be an expensive PITA!!! I hope they take care of this satisfactorily.
 
take a pic of the cell top, are these single stud or dual stud cells? gonna guess dual. 2 versions of these BYD cells. single stuff seems newest and tests best for me.
 
Only other pics I have
 

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I would let them know you’re posting on all solar forums about what’s happening. ? Might get their attention. Can’t hurt.
 
I purchased my LG Chem Chevy Bolt packs from Battery Hookup and they were very cool to deal with. These packs seem to be near new, but I have not been able to do a real capacity test yet. From my limited experience, these guys seem very reputable. One of my Bolt packs had the buss bar bent over, and they gave me a $25 credit for having to straighten it. I didn't even complain, I just mentioned it after a shipping delay on the third pack.

When they have used packs, they are usually very honest about the state of the cells. I found their ad for the BYD packs but it does say sold out now.


Unfortunately, since they no longer have any of them left, they can't send you another pack. In the description they did say they priced them at half capacity. It also says they guarantee "No Dead Cells". Wonder what the full term of that guarantee is? Have you measured each cell to see what they are at? In your pics, I can still see the two green straps around the pack, so they should still be under compression. The ad did warn not to cut the straps and you obviously have not, but the internal pressure is expanding out beyond the straps. Many pouch cells require pressure to keep them from expanding. The plastic plates don't look like they were able to take the stress. I have several old RC car LiPo packs that have bulged out and cracked the housing like that. The capacity does end up taking quite a hit when it happens, but I have not had any go into thermal run away from it. They just lose their current capability and become useless. At least LiFePo4 cells are inherently quite safe, so there should be little to no fire risk like a cell with Cobalt like my old LiPo's. Certainly try to work with the guys at Battery Hookup and see what they can do for you. If the cells do all measure useable and better than 1/2 capacity, maybe you can add some clamp force with stiff plates on the ends to stop the expansion and still use them.

They currently have a very good price on some 14S LG NMC packs, but they are only testing at 2/3 of original capacity. To me, that is already saying they are cycled out and going downhill. The price is still good for the capacity they have left, but I have to be skeptical of how many cycles they have left before they quit completely. At the prices they have on some of their packs, you have to decide if the deal is worth it some times.
 
Only other pics I have

I have four BYD's that look very similar to these...but not exactly like them. Bought them real cheap from Battery Clearing house.
Everything went super until I decided to see just what they had in them....CRASH!!! lol
But, since then I have worked with them some more and I think I just have one cell that is pretty weak. By taking my time, using an active balancer, and using them as I normally would and not seeing how far I could push them, I think I now have a battery bank that will meet my needs very nicely. I Have four of them in parallel in my bus conversion/RV.
 
Load tested 1 of them today, not the extra bulgy one though. Needs more balancing, cells varied from 3.5-3.7v at start of the load test. Got 2.9kwh stopping at about 2.9-2.98 volt per cell. With a little more work I’m sure I could get 3k out of it.
 
Load tested 1 of them today, not the extra bulgy one though. Needs more balancing, cells varied from 3.5-3.7v at start of the load test. Got 2.9kwh stopping at about 2.9-2.98 volt per cell. With a little more work I’m sure I could get 3k out of it.
how did you hookup to the terminals? They seem to be something like a 7/16 inch stud?
 
I have tried using car battery terminals in a pinch. Trying to get a 3000 watt xenon lamp power supply back running at night, and only found an auto parts store still open. It all powered up, for about 10 minutes. Then the battery terminal melted off. 100 amps is less than cranking a car, but you only crank a car for a few seconds.
 
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