I only have the evolve charger do I need to buy extra tools to charge manually and monitor or do I just bypass BMS and monitor voltage every once in a while with voltmeter?
Yes just charge B0 and B10 and monitor the whole time. Storage charge on li-ion is about 3.6V to 3.7V – 3.45V is basically dead. It’s not super-important though. Just don’t let it get lower.
Thanks for all the help and suggestions. I charged the battery, bypassing the bms, to 3.63. I hoped this might fix the issues but unfortunately when connecting the plug to the VESC or when connecting the balance cable plug, the BMS still gets way too hot. I dont think it’s a balance cable issue because the pic below shows in green that the balance resistors are fine but the red-marked area is burned. Anyone know why this might be?
It’s a capacitor, but do you have a higher-resolution photo?
I’ll take one as soon as I get home from work.
That capacitor’s insides have blown out. Remove it and replace it with another 100V electrolytic capacitor, 4.7μF
Did you ever get the bottom of this?
I put a pack together using Lipo cells and the BMS MOSFETs get hot to touch. Charger is putting out 42v but it’s not getting to the pack. Cells were balanced first. Then I tried charging via the evolve charging system. Despite all cells @3.8v the charger went light green within half an hour. Got 4/5km out of it. Battery indicator dropped consistently over that distance and won’t recharge. Cell voltages are all over the place.
Remote indicates battery is flat.
Yes cell order on balance plug checked wiring ok. No shit stains on PCB
Cells weren’t new. But were all serviceable. Salvaged Multistars from my own packs. I know they were performing well.
Bought second hand. Previous owner complained about battery sag. I experienced the same symptoms. One cell in the original pack was a lot lower than the rest. So that’s why I went ahead and DIYed a replacement.
Unfortunately no, I didn’t. I gave up ordered a new BMS, vesc and remote.