Clearly the OP is doing something wrong, I just can't believe he had sevan faulty packs at the same time. Causes of cell failure include:
- Over-discharging. This means never below 3.5 volts per cell resting voltage. A default LVC of 3.0 volts is TOO LOW. Never discharge below 20% remaining capacity.
- Over-heating. Too high of an amp draw or running too lon = heat builds up. What is a safe amp draw for 2 minutes may not be for 4 minutes. (BTW 105*F is just starting to get warm.....not anywhere near too hot.)
- Over-charging. Too high of a charge rate will shorten cell life. A 1C charge rate is always fine.
- Poor balance. Some packs may require balancing every charge, some do not. ALWAYS check balance before charging.
- Storing at full voltage. This can reduce capacity and can cause puffing. Store at 3.85-3.90 volts per cell.
- Inadvertant shorting. Plugging the pack leads together will cause sparks, can damage some packs internally.
Puffing is almost always caused by overheating the cells. Excessive cell temperatures cause cracks in the electrodes allowing the electrolyte to react with the surface releasing gas, which causes the swelling.
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