sunshine_eggo
Happy Breffast!
I appreciate the confidence you write with, it gives me (an Ignorant not Stupid man) confidence on how to proceed.
I'm a cocky bastid.
That said and according to your statements I will use maintain the four banks with the best matched cells (has to better) and the fifth I will use the 90AH with the other 7 cells including the 160Ah.
That's a little bit opposite of what I suggested. Yay on the 4, but building a battery with cells ranging from 90-160Ah is pushing it a bit. If it's temporary, before replacing some cells, then that's fine.
Each 8S battery has a capacity equal to the lowest capacity cell in the string.
I'm gonna have to step out on a limb here and say that in doing so with that last bank, it will require me to removing or increase the BMS variation setting as it will soon shut down that bank; yes I will top balance them to 3.65 before letting them carry any loads.
You really shouldn't be using a max to min cell variation for cut off ESPECIALLY if you have known cell variations. Setting it to 0.1 or 0.05 or 0.2V doesn't benefit the cells in any meaningful way and is usually just inconvenient as hell. If you have to set it to something, maybe 0.5 as things will have gotten pretty wonky at that point.
Top balancing + passive BMS balancing should be sufficient IF your cells have reasonable self-discharge rates. The most likely thing that's going to make this unworkable is if the self-discharge rates are too dissimilar.
Side note: I have tested all cells for IR and the difference is between .380 to .650 ohms
Did you find an inverse correlation? High cap cells were towards the low end of the range and low cap cells were at the high end of the range? That's consistent with cycle life and capacity degradation.
While those numbers aren't inherently bad, the high is nearly double, which means 2X the voltage drop for a given current. This may also prove to be problematic.
Passive balance should be set to occur any time the cells are above 3.40V and with > 20mV deviation. Ideally, you'll want your cells in the balancing range a couple of hours per day. Some BMS only balance during charge. Hopefully, that's not the case with the DALY. With the JBD/Overkill, you can enable/disable "balance during charge only" or whatever.
If you can tolerate a slower charge rate and still get fully charged, charging to 3.45V/cell, 27.6V and holding for two hours plus a float of 3.40V/cell or 27.2V should minimize charging stress and help ensure the balancers get lots of time to balance every day.