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Old 28th Jun 2011, 3:35 pm   #1
neon indicator
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Join Date: Jun 2010
Location: Co. Limerick, Ireland.
Posts: 1,183
Default Battery box and socket details.

I'm designing some battery valve stuff and I know little about the Traditional 1950s battery packs.
I remember the WS 88 that fitted an Ammunition pouch and 1.5V + 90V battery in the other pouch.
I remember a "Lady Margaret" or similar portable that I fitted a mains eliminator into when I was 11 or 12. Also a wooden cabinet radio that took a battery pack.

Is there any site or list of standard battery packs and sizes? Maybe even with package artwork I could print?

Additionally I want to adapt internals of package and connector.

My needs
Possibly 3 off identical 48V nominal rechargeable packs with 1.3V NiMH for heaters in one "suitcase" radio. Each of the 3 LT batteries would power 1/3rd of the filament power. On Receive the 3 x 48V HT are in parallel, and on Transmit two of the HT packs go in series with main 48V HT to give TX PA HT of 140V nominal. The 2 or 4 PA valves are used as audio PA on receive at 48V. The push-pull audio transformer drive connections will have 2 x RF chokes in series and provide 140V to 150V nominal HT to PA on transmit. The RF from PA will be to RX/TX relay via 2 x 470pF or 1nF capacitors to a common-mode choke/transformer as balun so it will not affect audio.

The end point of the NiMH is just under 1V and absolutely fully charged are near 1.47V (no load) dropping at once to about 1.35V under load, about 1.25V average as they discharge down to 1V. Some datasheets / experts claim 0.9V or even 0.8V is endpoint, but 1V is "safer" to avoid a weakest cell getting "reverse charged".

AA: 1800mAH to 2200mAH capacities are more reliable. The 2500mA to 2700mA types self discharge fast sometimes in a week and last for less cycles. Eneloop are supposed to be best.
AAA: 700mAH more reliable in long term than 1000mA
PP3: 180mAH is realistic. The 200mA or higher may be not as good, or optimistic.
C: 3500mAH is likely OK, 4000mAH? I don't know. If it's 2500mA and light suspect is really an AA.
D: Most are actually C cells or even AA. Only really a D cell if 4500mAH

A modern NiMH C cell is likely not much lower capacity than an old NiCd true D cell. A Nominal 24V military set may use 19 x D size NiCd. Only 18 x C size NiMH needed to give similar volts and capacity.

So any comprehensive list of dimensions and voltages of LT + HT dry battery packs?

I think possibly 65V rather than 90V for some radios. Were only hearing aid valves 22.5V, no Radios?
Telecoms uses nominal -48V since forever. It's actually about 40V to 56V really as "lead acid" derived. Real float charged Lead Acid Car batteries are 13.5V to 14.2V, not 12V. Use below about 10.5V on a 6 cell battery usually means the death of it.

NiCd and NiMH doesn't mind complete discharge, but only if all cells equally, thus with a battery of multiple cells the one to reach 0V 1st gets destroyed by reverse charge from the others. Thus on NiMH a nominal 48V pack using 40 cells is 40V at discharge limit to average 48V about 54V "fresh" and maybe nearly 60V on trickle charge. It might be an idea to limit end point to about 42 or 43V and for charger to supply nominal 48V as well as charge batteries "out of circuit" to have longer battery pack life and more consistent operation.

The problems of cell matching and charge limits are MUCH more severe on Rechargeable Lithium technologies as discharge or charge beyond a certain point can result in catastrophic failure.

Most high capacity Lithium and NiMH batteries can't be kept on trickle charge. The NiMH the trickle charge can't be maintained when full like NiCd. That wears out the cell. If there is trickle current on NiMH once charged, it must not exceed the self discharge current.

Last edited by neon indicator; 28th Jun 2011 at 3:40 pm.
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