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Thanks for your reply. It sounds like their bigger batteries have a different kind of construction. Threaded terminals would be much easier to deal with. For me to put my battery back together I'll have to buy a spot welder and learn how to use it. The cells that had 0 volts you threw away...

And here's a picture of the only marking on these cells. Anybody have any idea about what brand they are or how I might find out. I've asked Discover directly, but apparently it's "top secret". WTF?

I got the case open this morning and removed all 15 batteries from the bad string. It's pretty clear that one of the cells was defective (shorted?). Looks like it got hot and started leaking. Here are some pictures of the one damaged cell next to an intact cell.

I finally made some time to get into this battery. Today I removed the busbars for the bad cell. The busbars themselves are in good shape but the metal tabs that were spot-welded to the batteries didn't fare so well. Now that the individual cells are isolated is there any way that I can...

Maybe I wasn't clear. The battery I took apart has 4 subunits as shown in the picture. Each subunit contains 4 15P strings connected in series for a total of 60 cells per subunit. There is one bad 15P string in just one of the subunits. The other 3 subunits each have 60 good cells and those...

In another post I was attempting to repair a bad string of cells in a Discover AES 48V battery. After disassembling the battery and exploring my options it's looking like, short of radical "surgery", that the battery is toast. However, the way the battery is constructed there are 4 subunits of...

It looks like I'm running out of options so I'm leaning towards going into the unit and replacing all 15 cells with new ones. I know that they are 26650 cells, 3.2V, 3.8aH. Does anybody out there know what brand cells that Discover uses in their batteries? How important is it to use the same...

I have 6 of these batteries currently and ideally would like to ad this battery if I can repair it. I have a Lynk 2 that allows me to monitor the batteries and I'm assuming would not interface with the JK BMS.

So I would replace the Discover BMS with the JK? I was thinking that I would replace all 15 cells of the group. I was under the impression that once they sit at 0.0V for awhile they're not recoverable(?)

Would it be possible to replace all 15 cells in that string? It looks like to get in there I would have to break all the spot-welds, hopefully preserving the tabs on the busbar. Is there a good technique to do that? 26650 cells seem pretty common and inexpensive. What would be the technical...

Thanks. I really appreciate your suggestions.

Yes, it's definitely not possible to warranty, especially since I've taken it apart

I finally dug into this battery which wasn't terribly difficult. The outer metal case is screwed together and the lid comes off easily. There are 3 circuit boards that are exposed and can be unbolted and lifted off. Then there are a few more bolts that hold the main battery unit to the outer...

OK. I appreciate the optimism. I'll dig into it and share my findings sometime in the next week or two.

Does anybody know if it's even possible to repair this battery? I'm surprised that with all the LiFePO4 batteries out there that there isn't someone offering repair service.

I think it's doable but I may have to remove the battery itself from the case. It looks like everything is bolted together. Here's a screenshot of the diagnostics screen showing cell 3 with "1.000" Volts. According to Discover this is a default reading when the cell is really low and could...

Thanks for all your response. Warranty is not an option for several reasons: I'm not the original purchaser According to the data logs the cell was having issues way back in 2/23 and then allowed to sit for almost a year (by the original purchaser) I don't think the battery was officially...

I have a Discover AES 44-4800-3000 battery with less than 100 cycles that is showing one bad cell (0V) out of 16 (the rest are roughly 3.34V). I've had extensive conversations with Discover tech support and basically they are not set up to repair these and are very reluctant to offer much...