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Battleborn four BB10012 battery bank failure

I have just read this entire thread end do end. I cannot find any explination of the peoblem or short coming of the BB batteries mentioned. I'd really like to know what the problem was. Can anyonee enlighten me please ?

Sorry, I had not read the entire thread, my mistake. I found the explination of the problem n the first post.
Thank you,
 
Last edited:
RandyP said:
I have just read this entire thread end do end. I cannot find any explination of the peoblem or short coming of the BB batteries mentioned. I'd really like to know what the problem was. Can anyonee enlighten me please ?
Click to expand...
I'd wager money on this.

diysolarforum.com

Battleborn four BB10012 battery bank failure

This isn’t the first time on this forum that people have trusted their torque wrench and it failed them. Tighten it good, by feel, but don’t go overboard. Attempt to tighten each lug to more or less the same tightness. Fewer problems tend to come from tightening by feel than trusting a torque...
diysolarforum.com diysolarforum.com
 
If battleborn is getting grilled in the market, what about companies like Relion and Dakota Lithium? They must be getting grilled as well, but Instead someone posted about a 560AH 4s that Dakota is wanting $4069.00 for. But hey they'll throw in a free 20 amp charger...?‍♀️
 
featherlite said:
OP:

Were the batteries tightly secured and held against each other to prevent the batteries from shifting towards and/or away from each other? If the batteries were allowed to shift, the cables might be stiff enough to transfer pressure forces against the terminals.

I tried, but was not able to view the videos, so maybe you already addressed this issue in one of your videos.

I feel your pain and hope we can figure out whether Battle Born batteries have a design defect.
Click to expand...
I have had this same problem as posted earlier here. If you look at the photo on my post, the B+ terminals were loose. I did correct a few and saved them. I noticed the terminals are firmly adhered to the "lid" which I cut off. The terminal is NOT bolted directly to the bus bar inside but it is a plastic sandwich and the current passes through the bolt and nuts.

My theory, especially when I saw the charger that was being used unknowingly, is that the terminals overheated from a combination of the charger having weak alligator jaws and too high an amperage instead of .5C. This softened the plastic strip on the bus bar and it shrank or spread out. This developed MORE heat and exacerbated the poor connection.
 
JunglePower said:
I have had this same problem as posted earlier here. If you look at the photo on my post, the B+ terminals were loose. I did correct a few and saved them. I noticed the terminals are firmly adhered to the "lid" which I cut off. The terminal is NOT bolted directly to the bus bar inside but it is a plastic sandwich and the current passes through the bolt and nuts.

My theory, especially when I saw the charger that was being used unknowingly, is that the terminals overheated from a combination of the charger having weak alligator jaws and too high an amperage instead of .5C. This softened the plastic strip on the bus bar and it shrank or spread out. This developed MORE heat and exacerbated the poor connection.
Click to expand...
Which video are you referencing here?
 
Zapper77 said:
I'd wager money on this.

diysolarforum.com

Battleborn four BB10012 battery bank failure

This isn’t the first time on this forum that people have trusted their torque wrench and it failed them. Tighten it good, by feel, but don’t go overboard. Attempt to tighten each lug to more or less the same tightness. Fewer problems tend to come from tightening by feel than trusting a torque...
diysolarforum.com diysolarforum.com
Click to expand...
You would wager money on what? Finding what the problem was?
 
guzmane76 said:
Which video are you referencing here?
Click to expand...
My BB post has a photo of the melted plastic sandwich:
diysolarforum.com

Battle Born Victorious

Hello fellow solar gatherers, I am totally off-grid on an island. I have two BB powered systems. In one location are eight BB10012 in series/parallel 48vdc and the other six of the same for 24vdc. The eight in the 48vdc system have been operating flawlessly. I'm very pleased. However, I...
diysolarforum.com diysolarforum.com
 
JunglePower said:
My BB post has a photo of the melted plastic sandwich:
diysolarforum.com

Battle Born Victorious

Hello fellow solar gatherers, I am totally off-grid on an island. I have two BB powered systems. In one location are eight BB10012 in series/parallel 48vdc and the other six of the same for 24vdc. The eight in the 48vdc system have been operating flawlessly. I'm very pleased. However, I...
diysolarforum.com diysolarforum.com
Click to expand...
Woow. I see now. That's probably what happened to all four of my batteries. Crappy design to sya the least.
 
It seems from the picture the current flow is from a copper buss bar to a brass battery terminal via a stainless bolt, and a plastic spacer between the metal parts. It's not surprising the battery terminal a) gets hot and b) the bolt looses its clamping force.
 
Why don't they just ditch this barrel batteries and go with prismatic, probably would simply the install significantly.
 
mikefitz said:
It seems from the picture the current flow is from a copper buss bar to a brass battery terminal via a stainless bolt, and a plastic spacer between the metal parts. It's not surprising the battery terminal a) gets hot and b) the bolt looses its clamping force.
Click to expand...
What I do not understand is why the terminal is not bolted DIRECTLY to the bus bar with the equivalent sized hardware as the external terminal.
 
mikefitz said:
It seems from the picture the current flow is from a copper buss bar to a brass battery terminal via a stainless bolt, and a plastic spacer between the metal parts. It's not surprising the battery terminal a) gets hot and b) the bolt looses its clamping force.
Click to expand...
I have been studying battery current flow. When I was a kid, my grandpa told me voltage/current is drawn from the negative terminal and the charge current goes in the positive terminal.
If this is true, that means the positive terminals are overheating due to too high charging amperage. But what do I know?
 
JunglePower said:
I have been studying battery current flow. When I was a kid, my grandpa told me voltage/current is drawn from the negative terminal and the charge current goes in the positive terminal.
If this is true, that means the positive terminals are overheating due to too high charging amperage. But what do I know?
Click to expand...
Apparently not that current is the same through the circuit.
 
So, what did you do to remedy the problem? Was that terminal bolt actually loose? Did you think of actually removing the plastick from between the busbar and the terminal then reassemble it with the teminal actually contacting the busbar? Is it possible? Thanks for sharing the pictures
 
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