My experience, I've had two cells (maybe more, haven't tested all of them yet) that took less than 6 amp hours total to go from 3.33 volts to 3.65 volts. At 40 amp hours going in, that's less than 10 minutes. Yes, the voltage measured at the back is different. I'm just trying to explain, that ESPECIALLY with a 40 amp current, you can over charge a cell in less than 10 minutes. The correct way to do it, is to disconnect the cell or bank of cells, set the power supply to 3.65 volts or as close as you can get it, then hook up the cell or group of cells. Then you can adjust the current, and if it doesn't read 40 amps, it doesn't mean anything is wrong. Tweaking the output voltage to 3.9 in order to get the supply to output 40 amps means you can overcharge a cell in 9 minutes (obviously longer if you have a lot in parallel). Lower amperage supplies will take longer, but I would STRONGLY encourage people to set voltage to 3.65 without a cell attached, and then leave it. It's perfectly OK to have the supply output less amps, and is expected.I completed the first 64 with no issues, there is a large delta from what is shown to what the actual output is. From the front to the back you have a 1.2 to 1.4v delta. I would think a common mistake would have been for some to turn up the the voltage and not pay attention to when it stops. Throughout the charging I would adjust the voltage till it stopped then backed it down by .5 this kept it from running away and was very stable during the top balance on the first 64. I was up till almost 3:00am monitoring the batteries on the final leg. This battery that swelled was not charged or discharged it was merely in a bank of 64 wating to be top charged.
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