A man's hand is shown adjusting a black Bakelite dial on the front panel of an instrument. The instrument is contained in a wooden box, and to the left of the box, a thermocouple is inserted into the flame of an alcohol burner.

Reading A Thermocouple With Mercury And A Potentiometer

August 5, 2026 by Aaron Beckendorf 2 Comments

If you’ve ever thought about the nomenclature of electrical components, potentiometer stands out as a strange name, etymologically suggesting something like a voltmeter. In fact, the component took its name from a voltage-measuring instrument also named the potentiometer. [Alnwlsn] recently took a look at one such device, which was integrated into a thermometer, and the Weston cell used to calibrate it.

The potentiometer (instrument) has a galvanometer at its heart. One side of the galvanometer is connected to the center lead of a potentiometer (component) which spans a voltage source; the other side is connected to a reference voltage. The potentiometer can be adjusted until no current flows through the galvanometer, at which point both sides match the reference voltage. The reference voltage source can then be replaced with some other source, which can then be measured relative to the reference by adjusting the potentiometer until both the voltages match. The reference voltage source is a Weston cell, which uses two mercury electrodes, one amalgamated with cadmium, to produce a stable 1.018 volt reference; despite being 74 years old, this particular cell still measured at 1.017 volts.

In this case, the potentiometer was made to measure the voltage produced by a thermocouple. After calibrating the potentiometer and connecting an iron-constantan thermocouple, [Alnwlsn] tested it with ice and boiling water, and in each case it proved accurate. In a more extreme test, it captured the temperature difference between the base and the tip of an alcohol flame.

For a bit more on the history of similar devices, check out the history of Weston Electrical Instruments.

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Testing Hundreds Of Used LFP Cells Requires Some Automation

August 4, 2026 by Maya Posch 7 Comments

Although Li-ion cells have become a lot cheaper over the years, if you wish to buy hundreds of high-quality ones for that performance go-kart project, you may feel financially pressured into going for the option of stripping down years-old commercial battery packs instead.

While this is a financially sound option, you do have to figure out what the condition is of each cell before you happily stuff them into a new battery pack for said go-kart, as [Within Tolerance] recently did.

This is something that can be done manually, but for the 768 lithium iron phosphate (LFP) cells that were obtained for this project that’d be quite the tedious task. Hence it was decided to instead spend that time designing a system to automate this process, capable of charging, discharging, measuring and quantifying individual cells.

You can find the resulting Cell Goblin battery tester project on GitHub, which entails a custom PCB featuring an ESP32-S2 as the brains and associated software to monitor the process on a connected PC. Fortunately the issues on the PCB that are described in the video are claimed to be fixed in the repository version.

Using five of these dual-cell cell testers it was possible to run through the hundreds of cells with ten cells at a time. An internal resistance meter was also wired into the PC-based software via its UART. As of publication of the video the testing was still in progress, which gives some idea of how long it takes to work through those cells.

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Demonstrating LFP Battery Safety In Case Of BMS Failure

July 5, 2026 by Maya Posch 24 Comments

Generally, LiFePO₄ (LFP) batteries are quite safe and stable, but it’s still possible for something to go wrong, even something catastrophic, like the battery management system (BMS) developing a direct short. This is one of the tests required to be certified for the UL 2054 standard that targets household and portable battery safety. In a recent series of videos, [Will Prowse] demonstrates how a series of commercial batteries pass these tests, and how some still fail.

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Safely Using Old EV Batteries In Your Home Solar Setup

June 10, 2026 by Maya Posch 33 Comments

As straightforward as the concept of taking battery packs out of an old electric or hybrid car and reusing them for home power storage sounds, this thought process skips a few essential steps. As argued by [Ed] in a recent video based on his own experiences with high-voltage Nissan Leaf batteries in a home PV system, the main problem is that you’re taking a battery out of a larger system including a lot of the management hardware and software.

The referenced Battery Emulator project is an open source effort to create a suitable interface between these EV batteries, with the mentioned Nissan Leaf being just one example in the project Wiki, with the connection scheme shown in the top image. It’s also noted that the Leaf battery BMS is not designed to operate continuously, so they need to be restarted every day or so lest they become too inaccurate.

These and other things are all solid reasons why you have to be absolutely certain that you want to integrate these high-voltage battery packs into your 12 – 48V low-voltage DC system. You’re after all assuming all the responsibility of setting up a system that’s both safe and reliable, so having a good read through something like the Battery Emulator Wiki and sourcing first-hand experiences from the folk in this community would be a very wise first step.

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The Secret Wattcycle LFP Battery Downgrade

June 9, 2026 by Maya Posch 7 Comments

After recently reviewing a Wattcycle LFP battery sent over by the manufacturer, [Will Prowse] was made aware of some disturbing changes to the internals of batteries received by regular customers. Rather than the nice protected cables, thick solid metal busbars, braided wire and excellent build quality, the units that a regular customer – got as well as the one that [Will] bought off Amazon – all feature something more akin to what you’d find in a budget LFP battery, including a wide variety of LFP cells.

With these LFP batteries generally coming in fully opaque plastic cases, it’s really hard to tell what the internals look like without either going medieval on them or using less intrusive methods such as an X-ray machine. In this case more capable braided cables were replaced with regular cables that in a test showed a much higher voltage drop compared to the braided type.

Along with all the other changes between these batteries, this makes it impossible to rely on any reviews as a customer. [Will] notes that Wattcycle isn’t alone in doing this, and makes the case for more transparent cases for LFP batteries. After all, if you can see at a glance through the transparent case what the cables and wiring looks like, what BMS is installed and even what any LEDs on said BMS PCB are doing.

There are some LFP batteries with such a transparent case already, and with some smaller LFP batteries you can even pop the top off without having to resort to very permanent levels of violence, so this is not a problem without solutions. From a consumer perspective it definitely would be nice to see the internals as literal transparency from the manufacturer’s side, as well as an increased ability to monitor the battery for any thermal, leakage or other issues.

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Using Brand New NiMH Cells After Sitting 12 Years Unused

June 5, 2026 by Maya Posch 26 Comments

You know your batteries are old when their labels have faded. (Credit: DiodeGoneWild, YouTube)

After finding a pack of NiMH rechargeable cells that had never been used since buying them in 2014, [DiodeGoneWild] decided to test whether they could be tossed or not. After previously testing different brand cells that had gone high internal resistance after only about five years, he wasn’t expecting much. Amazingly, the batteries not only recovered, but seems to be not that much worse off for wear.

Three of the four precharged cells still held some voltage and happily charged back up to their rated 2,000 mAh capacity basically with the first cycle. One of them read 0V initially, but was revived using the typical manual charging approach involving a bench power supply. After a few charge-discharge cycles only the deep discharged cell showed some noticeable degradation with slightly reduced capacity, but all of them read healthy internal resistance values.

What this mostly shows is that not all NiMH cells are made the same, with the Tronic ones that previously failed after a few years doing much worse than these Activ Energy cells which are apparently sold primarily at Aldi stores. Overall NiMH is a pretty robust battery chemistry, so it’s always worth it to try reviving a cell before tossing it.

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Testing LFP Battery Failure Modes With Overcharging

May 28, 2026 by Maya Posch 33 Comments

As great as batteries are, it’s essential to understand their risks and how to keep them from going spicy. Recently there has been a bit of a fuss about the dangers of LiFePO₄ (LFP) batteries after someone’s dedicated LFP battery shed got shredded into matchsticks by a hydrogen explosion, following said LFP batteries having a thermal event. The thing about the LFP chemistry is that if it suffers such a thermal event, it generates hydrogen gas, which is one of the most explosion-happy gases known to man. This is demonstrated in a recent video by [Will Prowse].

To kick things off, a single prismatic LFP cell is overcharged for half an hour after it was already at 100% state of charge. This ultimately pops the vent as the cell begins to release hydrogen gas into the aquarium that the cell was placed in. Using a spark generator it’s then attempted to ignite the gas, which initially takes a bit as enough hydrogen has to collect first.

Once there’s ignition, however, it happily keeps burning as more and more hydrogen pours out of the by now bulging cell’s vent. If any other LFP cells had been nearby these too would be at risk of suffering thermal runaway, showing how just one bad LFP cell is enough to potentially set an LFP battery bank ablaze.

In a commercial setting you will have precautions such as hydrogen sensors, ventilation and spark generators to deal with any generated hydrogen gas, as well as blow-out panels in case things end up going squirrely in a hurry.

While a benefit of LFP chemistry is that it does not generate its own oxygen as with other lithium-ion chemistries, hydrogen gas is a major problem due to how incredibly volatile it is. It’s not just a headache with battery storage, but also in the nuclear power sector, where zirconium fuel rod cladding can very efficiently turn steam into hydrogen and oxygen. This was the reason why some of Fukushima Daiichi’s buildings suffered detonations, with the nuclear plant operator opting to not install recommended hydrogen gas mitigation systems.

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