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I read several documents about building batteries (e.g., for photovoltaic systems). I still have questions.

1.) LiFePO₄ cells have an internal resistance of a few mΩ. If you connect two such cells with different states of charge in parallel, shouldn't there initially be enormous currents?

If so, how can you create a common state of charge that allows safe parallel connection?

  • Option 1: Balance the charging voltage with a suitably sized resistor
  • Option 2: Establish same charging voltage by charging/discharging up to a deviation in the millivolt range
  • Option 3: Put them in series and implement a balancing circuit

2.) It is recommend to have same "age" SOH of cell connected in parallel. What is the easiest way to determine batteries with same state of health from a given set?

3.) Is the series connection of cells with different SOHs harmless or is there a risk of over-charging when using a charge transfer balancing circuit?

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  • \$\begingroup\$ ... adjusted. thank you \$\endgroup\$ Commented Jul 3, 2023 at 18:11

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If you connect two such cells with different states of charge in parallel, shouldn't there initially be enormous currents?

Yes. That why you must never do that.

how can you create a common state of charge that allows safe parallel connection?

Ideally: Charge each cell with a single-cell charger up to the maximum voltage (3.6 V for LFP Li-ion cells). Then connect the cells in parallel. All the options you listed are not as good, because the Open Circuit Voltage (OCV) of an LFP L-ion cell is very flat over a wide range of SoC levels.

It is recommend to have same "age" SOH of cell connected in parallel.

That is not a critical requirement. New cells from the same source will have the same SoH. If you're recycling old cells, having the same SoH is the least of your worries.

What is the easiest way to determine batteries with same state of health from a given set?

Determining the SoH of a Li-ion cell is best done with specialized equipment. The easiest way is to buy a Chinese cell tester.

Without it, you can get a rough idea of the SoH of a cell with two parameters: capacity and series DC resistance. Measure the capacity of the cell by fully charging it, then discharging it through a constant load and integrating the current, until the cell reaches a low voltage cutoff. Measure the resistance of the cell by applying a load and measuring the drop in voltage, divide by the current.

But, again, you're overthinking it.

Is the series connection of cells with different SOHs harmless

Yes, as long as they are protected by a properly-installed BMS.

is there a risk of overcharging

No, as long as they are protected by a properly-installed BMS.

when using a charge transfer balancing circuit?

Charge transfer balancing ('active") is pointless in your case. Forget it. Use plain-old bypass balancing ("passive") instead.

Regardless, this question is moot because the idea of balancing cells in series before connecting them in parallel is a needlessly complicated solution.

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  • \$\begingroup\$ Thank you Davide for accurate answers. Last question actually refers to series. My idea to have e.g. 3 cell in parallel and line these triples up in series, for increased capacity and limited cable work for the balancer. \$\endgroup\$ Commented Jul 3, 2023 at 18:09
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    \$\begingroup\$ "Last question actually refers to series". Start a new submission and ask that question separately. Otherwise, they will remove this question for "lacks focus". \$\endgroup\$ Commented Jul 3, 2023 at 20:34

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