One thing about series connected batteries. A high resistance connection at one of the post can cause the whole bank to get cooked/overcharged.
Especially when there is a large charging
source. Last week a customer called me to tell me he had a problem. "all of my battery tops are cracked and leaking acid everywhere"
My initial diagnosis of the problem, was a run away alternator
based on the fact the Mr Customer had just returned from a 6 hr run. This battery bank was 1 year to the week old. It was made up of 8 x 8 volt Interstate bats to make to make 32 volts, 4 x series, 2 x parallel. Mr Customer installed the bank. I installed a new Outback inverter
, AC panel, 50 amp alternator
and BatMon, along with bat fuses
and bat switches. The bats were installed to a shelf not in boxes and cribbed only on three sides.
I counseled Mr. Customer on the need to put the batteries in spill proof boxes and secure to said shelf on all 4 sides as well as tie downs. He said "you don't worry about that I will put the bats in boxes, and secure them".
He paid $225.00 US dollars for each of these bats, a grand total of $1800.00. They were murdered after one year of life, they spilled and spewd battery acid all over the engine
room, he's very lucky that the boat didn't burn to the waterline.
Final diagnosis after inspection
of the bats. 1st Mr. Customer had never gotten around to putting the batteries in boxes, or cribbed and tied down said bats. 2nd the jumper on one of the series connected bats developed a high resistance connection. This was caused by a poor crimp, and the fact the bats were able to move around while underway.
This connection turned one of the paralleled banks into a 28 volt nominal, said 50 amp alternators job was to charge the bank at 39.5 volts, this caused the alternator to actually charge much higher in amperage and voltage to bring the 28 volt bank up. This cooked 7 out of 8 of the batteries, the only bat that didn't crack and spew was the one with the high resistance connection.
To solve the problem, 8 new 8 volt Trojans to make the bank, all new battery cables
made by me this time. All in boxes and secured properly. The alternator sent to the shop for testing, and a rework of the regulator
to externally controlled, and the addition of of a Balmar
M632 4 step regulator
, with temp sensors for each bank.
I will only install smart charging/regulation, but if you don't install temp sensors to the smart charging sources then the charging source is going to do what it's designed to do...charge to 2.5 volts per cell(FLA's).
With out temp sensing, and with a high resistance at the cell level or the series connected bat you will end up with a potential fire, or at the very least murdered bats.