SAVE THAT PLANE Learning about batteries FREE TOOL

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SAVE THAT PLANE Learning about batteries FREE TOOL - 2/21/2009 4:03 AM

sticktickler

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When you consider the extremely important task the battery packs have in an RC aircraft one can begin to realize the monumental faith we place upon them. The battery pack is the onboard pilot in the model in a sense because there is really nothing to compare its significance in a full scale aircraft other than the pilot. Arguably I believe the RX & TX battery pack is the weakest link in our flight system, even the smallest anomaly can lead to certain disaster.

Unfortunately many beginners and even seasoned flyers consider the battery pack nothing less than a necessary enigma. But something this important should never be looked upon to just do the job blindly. Proper battery maintenance is paramount to the ultimate success of any well kept RC flight hanger.

Yes we have load engineered lighted switches and meters to check levels at the field which can be very helpful. However nothing can tell you more about your batteries condition over time than a well managed battery cycling regiment. Which is the charging and discharging of the pack down to a predetermined cutoff voltage to achieve an accurate Milliampere-hour or(mAh) reading with an instrument designed to do just that called an analyzer.

One ampere-hour is equal to 3600 coulombs (ampere-seconds), the electric charge transferred by a steady current of one ampere for one hour. So the mAh is one-thousandth of an ampere-hour or 3.6 coulombs. With a good analyzer (many are available in the hobby) we can measure the mAh drawn from the pack under a load similar to the flight system over time. Having this knowledge is like peeking into the pack through a window and seeing its fuel level, but even better.

The trick is to learn what this data is telling you so your battery is no longer an enigma just doing a job with blind faith. It is necessary to run at least three or more test per pack and then multiply that into an average. Then divide that average by the packs rated mAh capacity which gives you the percentage of the packs actual mAh capacity available for use.

The RC industry standard acceptable flight limits for most Nickel-Cadmium (NiCd) and Nickel-Metal Hydride (NiMH) battery packs is 70%. To determine the 70% capacity mark for your pack simply multiply its labeled capacity by 0.7. When packs mAh capacity is less then 70% of it's labeled mAh capacity a battery anomaly is present and it should not be used . Now under most conditions replacement is recommended with some exception which I’ll show you later on.

So we now have a better understanding of how to measure a packs mAh and using the above formulas to calculate its usable capacity. But doing this time and time again can really be a numbers game. So to manage those numbers we need some help and for my money there is no better help for that task than Microsoft Excel spread sheet software.

Here’s where things get real interesting and let me tell you NOTHING can give you this much information about your batteries condition at a glance. I took care of all the formulas for you in Excel. You DO NOT need to be a computer genius or a Einstein mathematician to use this spread sheet. Simply enter the tested data you get from your analyzer into the proper cell (light blue cells) and all the math is done for you. Even the line and percentage graph updates automatically so easy my 9yr old daughter can do it. How cool is that?

All the data in the graphs below are related and change as you input more data in the light blue cells. Now we can get a much better picture of how the pack is doing over time. Let me direct your attention to the line graph below. We can see pack 2 the 1800 mAh pack clearly has a problem but seems to level off at 70%. Not the best situation but with careful monitoring of this red line shows we now have a 800+ mAh pack we can use in a trainer or something. So the larger 1800 mAh pack near 70% is not always junk as long as it shows a consistent mAh capacity level (as the red line graph shows) it’s still usable just not for the heavy duty tasks of a usual 1800 mah pack for the larger planes. Or simply bust it apart and use them in your glow igniter is what I do. Now look at Pack 10 the 600 mAh pack it’s at 70%. I would junk this pack quick a 30% loss of a 600 mAh pack is not good for anything at all.

Now look at pack 3 the 1400 mAh pack see the drop off in the line chart but notice how it's coming back up. Old NiCd packs can in fact do this they will get better with continued cycling over time. Just keep testing it and make sure the mAh remains consistent over time when it does come back up. See pack 1 the first 1800 mAh pack this is ideal a true dream pack you can put this into any costly project and feel confident it will not fail you.

If anyone wants this Excel spread sheet file just PM me I’ll send it to you e-mail. Anything I can do to keep the planes in the air and out of the trash can makes me happy.

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RE: SAVE THAT PLANE Learning about batteries - 2/21/2009 8:55 AM

hugger-4641

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Sure, e-mail it to me, I don't have an analyzer yet, but will probably get one sooner or later. I have about 30 nicad motor packs, a dozen lipo's and half a dozen rx nicad packs that I try to keep up.

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RE: SAVE THAT PLANE Learning about batteries - 2/21/2009 9:13 AM

sticktickler

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You need to go up to the FORUMS tab above and go into the PRIVATE MESSAGES area and send me your e-mail address you don't want to post that on a open forum, I'll send it right out.

< Message edited by sticktickler -- 2/21/2009 9:15 AM >

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RE: SAVE THAT PLANE Learning about batteries - 2/21/2009 9:56 AM

Ram Jet

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quote:

ORIGINAL: hugger-4641

Sure, e-mail it to me, I don't have an analyzer yet, but will probably get one sooner or later. I have about 30 nicad motor packs, a dozen lipo's and half a dozen rx nicad packs that I try to keep up.

If you are looking for a charger this came from a very reliable source:

http://www.acehobby.com/ace/chargers.htm

Bill

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RE: SAVE THAT PLANE Learning about batteries - 2/21/2009 10:01 AM

sticktickler

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Ram Jet,
Did you get that Excel file to open on your PC yet?

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RE: SAVE THAT PLANE Learning about batteries - 2/21/2009 10:36 AM

Ram Jet

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quote:

ORIGINAL: sticktickler

Ram Jet,
Did you get that Excel file to open on your PC yet?

Yep, after I went to Microsoft to get a patch (compatibility pack) because of my antique version of Excel. I got a warning that your software was created on a newer version of Excel so color matching would be close but not exact. Like I care about colors. It appeard to have downloaded just fine. Now, I'll have to tap my brain cell reserve and make it work. Thanks Stick.

Regards,
Bill

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RE: SAVE THAT PLANE Learning about batteries - 2/21/2009 10:54 AM

sticktickler

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Imagine the smell of smoke in my house from my over used brain cells designing it.

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RE: SAVE THAT PLANE Learning about batteries - 2/21/2009 11:01 AM

Ram Jet

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quote:

ORIGINAL: sticktickler

Imagine the smell of smoke in my house from my over used brain cells designing it.

Ya dun good stick, ya dun good.

Thanks,
Bill

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RE: SAVE THAT PLANE Learning about batteries - 2/21/2009 11:16 AM

sticktickler

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I also made up this cool kit build time sheet lets you know just how much time you spent on your masterpiece. It even shows your most and least productive days in a bar graph cool stuff to have when selling a nicely build project. Soon to have a plane specific flight hour log during the season spread sheet love this stuff.

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< Message edited by sticktickler -- 2/21/2009 10:46 PM >

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RE: SAVE THAT PLANE Learning about batteries - 2/21/2009 12:20 PM

telejojo

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Do A123 batteries need to be cycled?

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RE: SAVE THAT PLANE Learning about batteries - 2/21/2009 7:37 PM

Ram Jet

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Does the pope say mass, do bears frequent the woods? I don't know but I bet ol' stick does.

Bill

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RE: SAVE THAT PLANE Learning about batteries - 2/21/2009 10:26 PM

sticktickler

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Ram,
The Pope is THE Mass, and the bears own the woods!

< Message edited by sticktickler -- 2/21/2009 10:27 PM >

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RE: SAVE THAT PLANE Learning about batteries - 2/21/2009 11:38 PM

Ram Jet

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That must be why Dutchess Pelosi just blew $500,000.00 of our hard earned money to pay him a visit.

Bill

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RE: SAVE THAT PLANE Learning about batteries - 2/22/2009 6:11 PM

sticktickler

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UPDATE: Even better color coding faster battery reference on all three charts all use the same color code very cool! What a sweet tool don't fly without it just PM me your e-mail and it's yours for FREE! yes I said FREE![/size]

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RE: SAVE THAT PLANE Learning about batteries - 2/22/2009 11:03 PM

JPMacG

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Nice graphics and nice presentation! Thanks for making your software available.

I have always been unsure of the proper criteria for deciding a pack is good or bad. I have heard that a NiCd pack that cycles to less than 80% of capacity should not be flown. I have also heard that a NiCd pack that self-discharges by more than 15% in a 5 day period should not be flown. I have also heard that a pack should be replaced at a regular time interval, like 3 or 4 years.

The real thing we are trying to avoid is a sudden pack failure in flight. A pack that gradually loses capacity over its lifespan is ok provided that we stay on top of it. But a pack that suddenly fails without warning is a very bad thing.

So, I'd like to hear others comment on the subject.

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RE: SAVE THAT PLANE Learning about batteries - 2/22/2009 11:35 PM

sticktickler

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Yes the key here is CONSISTENCY over time. Lets look at it this way, each test you do on a pack is the equivalent of a days flying. That being said lets look at pack 4 in the purple ling graph below. If this pack was flown rather then being dumped for a test on the 7th cycle you would have crashed painfully soon into the flight. Not even an expand scale meter can tell you that at the field right after a full charge it would have showed acceptable after cycle 6. Long flat lines are what you want, the numbers are nice but even they don’t show you the data like this graph can. Simply put a picture is worth a thousand words or in the this case maybe a $1000.00 the cost of replacing your plane.

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< Message edited by sticktickler -- 2/22/2009 11:39 PM >

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RE: SAVE THAT PLANE Learning about batteries - 2/23/2009 3:36 AM

sticktickler

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Lets get them packs tested come get your FREE cycling chart now before the season starts!

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RE: SAVE THAT PLANE Learning about batteries - 2/23/2009 8:55 AM

sticktickler

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quote:

ORIGINAL: JPMacG

So, I'd like to hear others comment on the subject.

Lets talk about the all fearsome NiCd memory effect for a moment. Firstly, the term memory effect is not an accurate analogy of what is happening. People tend to attribute most anomalies of a NiCd to memory effect. Let us define memory as the phenomenon where the discharge voltage for a given load is lower than the rated pack. This can give the appearance of a lowered capacity, while in reality, it is more accurate to term it voltage depression. Memory is also hard to reproduce in a lab environment which makes it difficult to study accurately.

Let us look at various causes of "memory" or voltage depression. Memory can be attributed to changes in the negative or cadmium plate. Recall that charging involves converting Cd(0H) to Cd metal. 2 Ordinarily, and under moderate charging currents, the cadmium that is deposited is microcrystalline (i.e. very small crystals). Now, metallurgical thermodynamics states that grain boundaries (boundaries between the crystals) are high energy regions, and given time, the tendency of metals is for the grains to coalesce and form larger crystals. This is bad for the battery since it makes the cadmium harder to dissolve during high current discharge, and leads to high internal resistance and voltage depression.

The trick to avoiding memory is avoiding forming large crystal cadmium. Very slow charging is bad, as slow growth aids large crystal growth (recall growing rock candy). High temperatures are bad, since the nucleation and growth of crystals is exponentially driven by temperature. The problem is that given time, one will get growth of cadmium crystals, and thus, one needs to reform the material. Partial cycling of the cells means that the material deep with the plate never gets reformed. This leads to a growth of the crystals.

By a proper execution of a discharge/charge cycle, one destroys the large crystal cadmium and replace it with a microcrystalline form providing a better more accurate pack discharge for the plane. Which is way we see continued improvement in older packs during the cycling regiment.

< Message edited by sticktickler -- 2/23/2009 9:01 AM >

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RE: SAVE THAT PLANE Learning about batteries - 2/23/2009 10:26 PM

sticktickler

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MORE UPDATES: Ok if you have MS Excel 2007 GREAT! We now are using some of the cool graphic features of this software for designers like myself to employ. See how the entry cells get lighter as the mAh drops and we now also have small colored waning signs to inform us of good and bad mAh levels right on the spreadsheet SWEET. These new features are sadly only available on the newer Excel 2007 real cool tool!

SO PM YOUR E-MAIL FOR YOUR FREE COPY NOW & BE BATTERY SMART!

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< Message edited by sticktickler -- 2/23/2009 10:30 PM >

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RE: SAVE THAT PLANE Learning about batteries FREE TOOL - 2/24/2009 10:52 AM

sticktickler

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Another free spreadsheet if you like to log your flights then this is for you. A full month flight log with fully editable plane list for over 30 planes. You could keep track of minuets flown or oz. of fuel used per plane. Keep track of what ever you wish on this useful sheet.

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RE: SAVE THAT PLANE Learning about batteries FREE TOOL - 3/2/2009 5:58 PM

spitfire66

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Hello,

Good stuff and sticktickler I e-mailed you about the software. I have a question though. I was looking at battery chargers and was wondering if there are battery chargers that have an analyzer in them or if you need to buy that seperate. Also I have had some recommendations on some chargers. I am looking at the hobbico accucycle or the turnigy accucell-6 on hobbyking.com. Not sure which one to get. I would like one charger to perform all functions naturally. Sure appreciate your help before the season starts!

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RE: SAVE THAT PLANE Learning about batteries FREE TOOL - 3/2/2009 7:07 PM

sticktickler

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quote:

ORIGINAL: spitfire66

Hello,

Good stuff and sticktickler I e-mailed you about the software. I have a question though. I was looking at battery chargers and was wondering if there are battery chargers that have an analyzer in them or if you need to buy that seperate. Also I have had some recommendations on some chargers. I am looking at the hobbico accucycle or the turnigy accucell-6 on hobbyking.com. Not sure which one to get. I would like one charger to perform all functions naturally. Sure appreciate your help before the season starts!

Well there are lots of great chargers and analyzers to choose from in our hobby most all do the job very well. Hobbico’s Accu-Cycle is a fine choice I own one myself it was given to me by an old friend who never used it, HE CRASHED A LOT TOO. This unit will charge, analyze and condition the pack over time the manual is also very detailed lots of good information. I also am quiet fond of ANY product ACE RC makes for battery charging and analyzing packs. The digipace 3 they make is the flagship analyzer in RC it will SLOW overnight charge the packs, which is a better way to charge the packs for testing anyway. They do however sell a very nice quick charger called THE SMART CHARGER designed to speed up charging for flying and field use as well becouse it runs from a 12 volt power sorce. So simply keep that plane plugged in and charging on the flight line always ready for use.

I own all the above products all are just wonderfully useful tools. If used with my FREE software you’ll never be in the dark about your packs flight worthiness again.

Remember it's not so much which analyzer you use, it's what you do with the data it gives you so you can learn about the packs capacity and fly safely. Be battery SMART!

See ACE at: http://www.acehobby.com/ace/chargers.htm

< Message edited by sticktickler -- 3/2/2009 7:14 PM >

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RE: SAVE THAT PLANE Learning about batteries FREE TOOL - 3/5/2009 3:12 AM

spitfire66

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Alright, getting started. I bought a hobbico accu cycle today and started to discharge my 1500 mah nimh battery and will cycle when finished. My transmitter however would not discharge. I made sure the leads were correct, correct number of cells and all that. The troubleshooting guide said that it may need charging. When I turn on my transmitter it beeps and shows it's about to die so I will try to charge it first. I will let you know how it turns out. Thanks for the excel program, I love to tinker with things and this will give me something to do.

Shannon

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RE: SAVE THAT PLANE Learning about batteries FREE TOOL - 3/12/2009 4:24 AM

sticktickler

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quote:

ORIGINAL: spitfire66

Alright, getting started. I bought a hobbico accu cycle today and started to discharge my 1500 mah nimh battery and will cycle when finished. My transmitter however would not discharge. I made sure the leads were correct, correct number of cells and all that. The troubleshooting guide said that it may need charging. When I turn on my transmitter it beeps and shows it's about to die so I will try to charge it first. I will let you know how it turns out. Thanks for the excel program, I love to tinker with things and this will give me something to do.

Shannon

Just so you know most Futuba transmitters may not let some chargers or analyzer properly communicate back out from the TX packs charge port. Futaba has always installed a diode to prevent any possible short when removing the charge plug from the radio. This diode could also prevent the pack from discharging from that port. To bypass this problem simply remove the TX pack from the radio and hook the analyzer directly to the TX pack. JR radios have no diode BUT positive and negative are reversed just so you know if you plug a Futaba charger into a JR radio you’ll KILL IT DEAD DOG DEAD!

< Message edited by sticktickler -- 3/12/2009 4:25 AM >

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RE: SAVE THAT PLANE Learning about batteries FREE TOOL - 3/13/2009 4:19 PM

cloudwalker

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Hi guys, I bought a new 4 cell flight pack and after i had fully charged it i was settig up the throws on my new plane. After a VERY short time, the controls went hay wire. of course it could not be the battery , or so i thought, but it was. If i had just put the battery in without having to do any set up of the controls it would have been a verry expensive battery pack. Bill .

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