For the last 37 years when I replace the battery packs which is about 5 times and will be the 6th time in about 2 months, I use a rotating power brushes that slips over the battery post and inside a battery clamp. This takes less than a hour for 90 cells.
You will note under a magnifying glass, there will be deep and high scratch marks on battery post, terminals, battery clamps, and links. I do not apply any contact aid, because it takes a tremendous force to press them into a mirror finish. We do use a contact aid on some exterior electrical devices, but it works best using a high power hydraulic crimper. Does not work good if you are only tightening the soft battery connections to 65 to 105 inch pounds. The hard battery connections can be torque up to 15 to 25 foot pounds or as specified. If you do use a torque wrench, use the eye ball test. Tighten until you eye balls pop out. I do not apply any protection compound over the battery connections yet. I first will drive the EV for the first 5 miles with a battery load up to 200 amps. Check the torque of the connections and it is common to loss about 5 in. lbs. after each run. After about 5 more runs, than I will check the torque and do a contact surface inspection. These contact surfaces are now at a mirror finish. I then brush on petroleum jelly over the entire battery connection and links down to the surface of the battery. Eight to ten years later, they are still at a mirror finish when I replace them. Roland ----- Original Message ----- From: Martin WINLOW via EV<mailto:ev@lists.evdl.org> To: Michael Ross<mailto:michael.e.r...@gmail.com> ; Electric Vehicle Discussion List<mailto:ev@lists.evdl.org> Sent: Friday, August 08, 2014 2:18 AM Subject: Re: [EVDL] To Noalox, or Not to Noalox I think REAP's results speak for themselves. Brushing is quite a bit easier than sanding but just watch you dont short a pair of terminals if you are using a long steel-wired brush! But as Michael suggests, in a damp environment, such as a marine application for example, the Noalox might prevent moisture from penetrating the joint and increasing its resistance over time. On the other hand, just using some petroleum grease (or similar) would probably work just as well. MW On 8 Aug 2014, at 04:38, Michael Ross via EV wrote: > The theory that is being proposed is that the noalox or grease will provide > better results over some time in service - particularly where there are > dissimilar metals in contact. That makes sense to me. I like the idea of > brushing much better than sanding. But, fine grit polishing sounds OK to > me. > > I guess you have to buy the idea that the zinc particles in noalox do bind > up free oxygen, providing anodic protection within the joint. If the joint > was dry, and the grease does not deteriorate, then I I think it might be > speculative marketeering, and product differentiation that touts the zinc. > > It would be interesting to see this tested somehow. > > > On Thu, Aug 7, 2014 at 11:22 PM, Rick Beebe via EV <ev@lists.evdl.org<mailto:ev@lists.evdl.org>> > wrote: > >> REAP Systems in England did test that in a lab last year. You can see a >> video presentation they did on the EVTV web site. Go to video archives, >> August 16, 2013. A direct link is >> http://media3.ev-tv.me/news081613-iPhone.m4v<http://media3.ev-tv.me/news081613-iPhone.m4v>. The presentation starts at >> 23 minutes and the results are around 36 minutes. >> >> Instead of sanding they used a steel bristle brush to remove the tarnish >> from the terminals and busbars. They discharged the cells at 300 amps in >> 60 second bursts 30 times. The BMS was monitoring individual cell >> temperatures and if they exceeded 45C it would reduce the current. They >> strapped 7 100Ah cells together. >> >> With uncleaned terminals they got one cycle before having to reduce the >> current because of temperature. The warmest cell got up to 55C after 10 >> cycles. >> >> With cleaned terminals there was no reduction in current until after 11 >> cycles when the warmest cell got up to 45C. The warmest cell eventually >> got just above 50C but after those 11 cycles they'd already drawn half >> the capacity of the cells. >> >> Interestingly there was virtually no difference when they added the >> grease. So if you think the grease will help prevent corrosion that's >> fine. But it doesn't seem to do anything to help the connection. >> >> --Rick >> >> On 7/31/2014 12:43 PM, Michael Ross via EV wrote: >> >>> With aluminum, you just cannot expose bare un-oxidixed metal, it is not >>> possible to do this, so I am not happy with the sanding idea. The sanding >>> has to be helpful on some other basis if it is indeed helpful. >>> >>> Be interesting if someone has compared greased un-sanded to greased and >>> sanded. >>> >> >> >> >> >> _______________________________________________ >> UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub<http://www.evdl.org/help/index.html#usub> >> http://lists.evdl.org/listinfo.cgi/ev-evdl.org<http://lists.evdl.org/listinfo.cgi/ev-evdl.org> >> For EV drag racing discussion, please use NEDRA (http://groups.yahoo.com/<http://groups.yahoo.com/> >> group/NEDRA) >> >> > > > -- > Put this question to yourself: should I use everyone else to attain > happiness, or should I help others gain happiness? > *Dalai Lama * > > Tell me what it is you plan to do > With your one wild and precious life? > Mary Oliver, "The summer day." > > To invent, you need a good imagination and a pile of junk. > Thomas A. Edison > <http://www.brainyquote.com/quotes/quotes/t/thomasaed125362.html<http://www.brainyquote.com/quotes/quotes/t/thomasaed125362.html>> > > A public-opinion poll is no substitute for thought. > *Warren Buffet* > > Michael E. Ross > (919) 550-2430 Land > (919) 576-0824 <https://www.google.com/voice/b/0?pli=1#phones<https://www.google.com/voice/b/0?pli=1#phones>> Google Phone > (919) 631-1451 Cell > (919) 513-0418 Desk > > michael.e.r...@gmail.com<mailto:michael.e.r...@gmail.com> > <michael.e.r...@gmail.com<mailto:michael.e.r...@gmail.com>> > -------------- next part -------------- > An HTML attachment was scrubbed... > URL: <http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20140807/6140844a/attachment.htm<http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20140807/6140844a/attachment.htm>> > _______________________________________________ > UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub<http://www.evdl.org/help/index.html#usub> > http://lists.evdl.org/listinfo.cgi/ev-evdl.org<http://lists.evdl.org/listinfo.cgi/ev-evdl.org> > For EV drag racing discussion, please use NEDRA (http://groups.yahoo.com/group/NEDRA<http://groups.yahoo.com/group/NEDRA>) > _______________________________________________ UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub<http://www.evdl.org/help/index.html#usub> http://lists.evdl.org/listinfo.cgi/ev-evdl.org<http://lists.evdl.org/listinfo.cgi/ev-evdl.org> For EV drag racing discussion, please use NEDRA (http://groups.yahoo.com/group/NEDRA<http://groups.yahoo.com/group/NEDRA>) -------------- next part -------------- An HTML attachment was scrubbed... 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