Blast Your Battery’s Sulphates, Is It Worth It?

August 25, 2017 by Jenny List 55 Comments

When a friend finds her caravan’s deep-cycle battery manager has expired over the summer, and her holiday home on wheels is without its lighting and water pump, what can you do? Faced with a dead battery with a low terminal voltage in your workshop, check its electrolyte level, hook it up to a constant current supply set at a few hundred mA, and leave it for a few days to slowly bring it up before giving it a proper charge. It probably won’t help her much beyond the outing immediately in hand, but it’s better than nothing.

A lot of us will own a lead-acid battery in our cars without ever giving it much thought. The alternator keeps it topped up, and every few years it needs replacing. Just another consumable, like tyres or brake pads. But there’s a bit more to these cells than that, and a bit of care and reading around the subject can both extend their lives in use and help bring back some of them after they have to all intents and purposes expired.

One problem in particular is sulphation of the lead plates, the build-up of insoluble lead sulphate on them which increases the internal resistance and efficiency of the cell to the point at which it becomes unusable. The sulphate can be removed with a high voltage, but at the expense of a dangerous time with a boiling battery spewing sulphuric acid and lead salts. The solution therefore proposed is to pulse it with higher voltage spikes over and above charging at its healthy voltage, thus providing the extra kick required to shift the sulphation build up without boiling the electrolyte.

If you read around the web, there are numerous miracle cures for lead-acid batteries to be found. Some suggest adding epsom salts, others alum, and there are even people who talk about reversing the charge polarity for a while (but not in a Star Trek sense, sadly). You can even buy commercial products, little tablets that you drop in the top of each cell. The problem is, they all have the air of those YouTube videos promising miracle free energy from magnets about them, long on promise and short on credible demonstrations. Our skeptic radar pings when people bring resonances into discussions like these.

So so these pulse desulphators work? Have you built one, and did it bring back your battery from the dead? Or are they snake oil? We’ve featured one before here, but sadly the web link it points to is now only available via the Wayback Machine.

Portable Battery Bank Only Looks Like A Bomb

September 5, 2016 by Dan Maloney 30 Comments

If one of the design goals of [wsw4jr]’s portable solar battery bank build was to make something that the local bomb squad would not hesitate to detonate with a water cannon if he leaves it unattended, then mission accomplished.

We kid, but really, the whole thing has a sort of “Spy vs. Spy” vibe that belies its simple purpose. A battery bank is just an array of batteries, some kind of charge controller, and an inverter. The batteries are charged by any means possible – in this case by a small array of solar panels. The mains output of the inverter is used to power whatever doodads you have.

[wsw4jr] didn’t mention of the inverter specs, but from the size of the batteries and the wiring – both of which he admits are not yet up to snuff in his prototype – it’s a safe guess that the intended loads are pretty small. Tipping the scale at 60 pounds, the unit tends toward the luggable end of the portability scale. Still, this could be a great tool for working out in the field, or maybe even tailgating.

We’ve seen expedient battery banks and emergency power from cordless drill batteries before, but this build is quite a bit more sophisticated. We’ll be watching for updates on this one.

Parts Bin Emergency Lights Deal With Tornado’s Aftermath

December 28, 2015 by Dan Maloney 27 Comments

Sometimes having a deep inventory of parts in your shop is a pain – the clutter, the dust, the things you can’t rationally justify keeping but still can’t bear to part with. But sometimes the parts bin delivers and lets you cobble together some emergency lighting when a tornado knocks out your power.

It has been hard to avoid discussions of the weird weather in the US this winter. The eastern half of the country has had record warm temperatures, the west has been lashed by storms, and now December tornadoes have ripped through Texas and other parts of the south, with terrible loss of life and wide-ranging property damage. [TheTimmy] was close enough to one massive EF4 tornado to lose power on Saturday night, and after the charm of a candlelight Christmas evening wore off, he headed to the shop. He had a bunch of sealed lead acid batteries from old UPSs and a tangle of 12V LED modules, and with the help of some elastic bands and jumper clips he wired up a bunch of lights for around the house. Safer than candles by a long shot, and more omnidirectional than flashlights to boot.

The power came back before the batteries ran out of juice, so we don’t get to see any hacks for recharging batteries in a grid-down scenario. Still, it’s good to see how a deep parts bin and good mindset can make a positive impact on an uncomfortable situation. We’ve seen similar hacks before, like this hacked cordless tool battery pack or powering a TV with 18650 batteries. Be sure to share your story of epic power-outage hacks in the comments below.

Laptop Running On A Sealed Lead Acid Battery

September 20, 2009 by Jakob Griffith 24 Comments

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[Viktor’s] laptop needed a new battery; he had the trade off between carrying around a cheap but heavy sealed lead acid (SLA) battery, or buying an expensive but light Li-Ion battery. Figuring his old laptop was pretty heavy already, and having an unused SLA available, re-purposing it for his laptop wouldn’t be too much of a hassle. Using a boost converter he built out of a custom dip MAX668, he is able to output the necessary 5 amps required. An MC 34161 voltage monitor chip is planned for future revisions, but he’s currently running it just fine. Check out some of his other cool hacks on Karosium.

Related: MSI Wind extended battery