I need to update the instrument battery portion of this thread. I am using 3 LiPo batteries that have a current limit of 12.6 volts and low of 10 volts as it falls off so quick as to just consider that the low limit. The low limit is actually 2.4 v per cell or 7.2v, but, once the cells get to anywhere near 10v they drop so quick. I had two instruments that would not boot with these batteries, but, would boot with a plugged source. Checking the Ohm's Law against what I was doing revealed the issue.
A Geodimeter takes 1.3 amps at 14.0 volts to boot, so, working that backwards 14.0v * 1.3amp = 18.2 watts. So looking at the efficiency of the regulator I was using yields 80% efficiency or 18.2 watts / 0.80 = 22.75 watts on the in side. With that info I can see the current needed to boot on the in side is 22.75/12 = 1.9 amps at 12 volts and 22.75/11 = 2.06 amps at 11 volts in. Basically I was right at the regulator limit on boot.
Placed a 5 amp regulator in this morning and every instrument boots and works fine. http://www.amazon.com/gp/product/B00MHTV8Z8?psc=1&redirect=true&ref_=oh_aui_detailpage_o03_s00 I had set this regulator to 14.0 volts, but, I am going to turn it down so input and output differences are minimized. Heat wasn't an issue with the 2 amp regulators, so, I am not expecting an issue with the 5's as they will not be close to their limit. It is all about real world efficiency though. This is only a step up regulator, so, I need to keep the output greater than 13 volts, me thinks
The lesson learned in both the 360å¡ batteries and the instrument ones is that I sized the regulators too small to begin with. The instrument regulators are in the 360å¡ batteries now and the instrument batteries are now 5 amps.
I ended up switching to a regulator that is purely step up, so, I stepped up the output voltage to 13.5 to make the instruments more happy and to make sure I had enough voltage ceiling for the regulators to work properly. That means that I am no longer close to the Parani input voltage of 5-12 volts, so, ... yes I added a step down regulator inside of our Parani boxes. This is the new regulator and it is 3 amp and will fix the issue with our current batteries. http://www.amazon.com/gp/product/B00EYT1D5O?psc=1&redirect=true&ref_=oh_aui_detailpage_o02_s00
For any new batteries I might make I have made more head room and enlarged the case. http://shpws.me/JNfx and will switch to this regulator http://www.amazon.com/gp/product/B00MHTV8Z8?psc=1&redirect=true&ref_=oh_aui_detailpage_o03_s00 
I did have to print one of the new ultimate surveying batteries and I have to say Shapeways stepped up their game. These fit so perfect, it is hard to believe that they are printed. I had to post this as I have given Shapeways a hard time when they screw up, so, it is only fair. This print has amazing fit and accuracy as does everything else in this order. For some commercial projects I have used the local guys because of their better quality, but, these are just as good. They were proud of their printing as well, because components that were separate parts were all put together in the box
I have two of these per crew so that they always have a backup. One crew hasn't used their backup in so long they are only carrying one now. I am still not comfortable with that, but, keep forgetting to say something (the bane of my existence) Bottom line is they last well past a day of hard staking and are light as can be imagined.
The pictures show a very slight gap, any finger pressure whatsoever closes them into one that is hard to see the seam
I noticed battery is very tight inside, if you have high drain device attached it may warm up and increase its size a bit and the plastic enclosure may not allow for that.
Tight was by design. I place a little layer of foam on the top just in case they decide to rattle as well. What I have found is the static cell actually gets smaller after it has been used for a bit and the foam is then needed. Most of the manufacturers silicone them in, which isn't a bad choice just not the direction I want.
The batteries that are installed in these have a 0.5C charge rate and the chargers are 1.5A so they are not even close to the 5.0A max charge rate (10.0 amp cells). As far as the drain side they have a 1.0C rating and even at boot the most an instrument takes is 1.5A, so, even calculating across a voltage difference of a couple of volts I can't see the drain being more than 2.5A. Basically, what I am saying is the drain and charge are so well below the maximums I don't think swell is a concern and we haven't seen an issue in the two years we have been running them. It not like an R/C car where you are taking several C's all at once. Great thought though
Norm, I didn't see any finished photos of the batteries. Is that in a different thread?
Well, I just went looking and, .. no I have never posted finished pics other than the first page of this thread. All of the wired ones are in the field with just the new print on my desk. I will post some pics when I can! There is this thread, but, it covers more the beginnings https://surveyorconnect.com/threads/printing-charging-equipment.234143/&apos ;">Printing Charging Equipment and this was a quick re-cell to LiPo thread https://surveyorconnect.com/threads/re-celling-to-lipo.270919/&apos ;">Re-Cell
Don't go out of your way.
Norm Larson, post: 355545, member: 7899 wrote: Tight was by design. I place a little layer of foam on the top just in case they decide to rattle as well. What I have found is the static cell actually gets smaller after it has been used for a bit and the foam is then needed. Most of the manufacturers silicone them in, which isn't a bad choice just not the direction I want.
The batteries that are installed in these have a 0.5C charge rate and the chargers are 1.5A so they are not even close to the 5.0A max charge rate (10.0 amp cells). As far as the drain side they have a 1.0C rating and even at boot the most an instrument takes is 1.5A, so, even calculating across a voltage difference of a couple of volts I can't see the drain being more than 2.5A. Basically, what I am saying is the drain and charge are so well below the maximums I don't think swell is a concern and we haven't seen an issue in the two years we have been running them. It not like an R/C car where you are taking several C's all at once. Great thought though
This is my "scared man" 🙂 design approach, it is good you newer reach high xC charge/discharge rates. The other thing is to look at is probably the operation temp, say if it is +35C outside, battery may expand more than enclosure... but I never did any research toward this
Great point. Western Washington isn't going to push that though!
Final got around to placing the new style battery in service. It has the enlarged head for a big 5A regulator. I placed the old style black batteries that these replaced in the background. 10 Amps that is a whole lot smaller and lighter
Some thumbnails
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Well the crew broke another backsight glass holder and we now have an FDM printer in house, so, what the hell, I gave it a try. FDM cannot print complex shapes without support for what would be free hanging, so, support material it did print.
This is not fun and this is an hour in. Laser sinter printing is looking good now, LOL. I am going to add an extra head to the printer, so I can print the support in water soluble material as I am not enjoying the cleaning of this. Oh well it is a stress relief to rip this thing apart.
There is an issue. Laser sintered nylon is very flexible and standard PLA is not. When we screwed the the screws in you can now see evidence that the pilot holes need to be larger as the PLA material is stress fracturing (not shown in pic)
I am going to re-try with flexible filament and two heads on the printer
Norm Larson, post: 242161, member: 7899 wrote: We normally don't review safety procedures when we implement new batteries, LOL. The real funny part is my guys were having trouble reporting it to anyone on site as they were all at a safety meeting. Well except for Lumpy.
Yes, Lumpy works for a very large company that will not even notice this as a cost and will be mainly concerned that no one was hurt.
Lumpy's company would sure as hell notice it if it was my equipment!
Question for anyone using alternate batteries to power the Trimble 5600's. I've heard of folks using 3S and 4S LiPo batteries. I believe they will both work, the 3S being 11.1V, the 4S being 14.8V, I'm wondering which I should go with?
I went 3S because it is just less weight. Regardless of what you go with, you will need a regulator to make it work seamlessly. Too low a voltage and the DC chirps at you, too high and you fry things. It you want to power a 360å¡ your voltage has to be exact or it won't work right. I have them now so I never have to cord the instrument and can level BT
Thanks Norm! I'm going to go with 3S and get a pair of 2650mAh for $25
We have a period of time where we have to run a Trimble S6 in passive mode and the crew told me that rain on the prisms slows down search a lot. So I modeled up a 5/8x11 thread rain hat for it and hit print.
I designed it to have a 1" drop and be 8" in diameter and looking at it in 3D, I decided it needed ribbing for strength. Well that is where it falls down a bit as I never visualized what the ribbing and the drop would look like on the rod. Yes, I have turned a S6 prism into a mai tai umbrella and it is sad ...
At least it is functional.
For those that don't know, I have switched to printing in house. The crew needed a rod for precision staking and I always liked the design of the Geodimeter rod with the exception of the joke of a level bubble they placed upon them. I bought a Seco 8' level vial and printed the center section to hold it. That center section is a complex bitch with lots of nooks and crannies and took more than an hour to clear the support material. If we need another of these, I will print as laser sinter so I am not cleaning support. It didn't help that I printed in poly carbonate ... This is way stronger than stock.
https://surveyorconnect.com/community/media/geodimeter-with-8-vial-1.36/&apos ;"> 
https://surveyorconnect.com/community/media/geodimeter-with-8-vial-4.39/&apos ;"> 
https://surveyorconnect.com/community/media/geodimeter-with-8-vial-1.36/&apos ;">
I was reminded that the pictures are gone, so, here are some pictures that hopefully help