18650 Garden-Powerwall with 50KWh in Germany

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Stefanseiner

Member
Joined
Apr 16, 2020
Messages
128
Yesterday I tried to build a mounting system as HB uses. First idea: to find a manufacturer who can build this and uses the CAD files HB provides in his thread

but then I decided to build it for my own out of an old 2mm metal plate
18650_Mounting_System_16s100p_01.jpg

18650_Mounting_System_16s100p_02.jpg

first I cut a template which I can use for the plasma cutter
18650_Mounting_System_16s100p_03.jpg

it's my first work with the playma cutter, so results ar far away from perfect...
18650_Mounting_System_16s100p_04.jpg


...but much better then with a angle grinder
18650_Mounting_System_16s100p_06.jpg



this will be the boddom part of the mounting plate
18650_Mounting_System_16s100p_07.jpg

for the top part I build a second template
18650_Mounting_System_16s100p_10.jpg

18650_Mounting_System_16s100p_11.jpg

18650_Mounting_System_16s100p_13.jpg


some work left for the angle grinder. Rounding the edges and grinding the metal slag
18650_Mounting_System_16s100p_14.jpg

I will not use a single plate but four parts because I will build up a 16s100p system and therefor a single metal plate would be very huge
18650_Mounting_System_16s100p_15.jpg

about 5 hours later
18650_Mounting_System_16s100p_16.jpg

drilling some mounting holes
18650_Mounting_System_16s100p_18.jpg

because I don't have a brake press I bend the brackets with a hammer
18650_Mounting_System_16s100p_21.jpg

sits and fits
18650_Mounting_System_16s100p_23.jpg

ready for painting
18650_Mounting_System_16s100p_24.jpg

I am using metal protective paint in anthracite...
18650_Mounting_System_16s100p_26.jpg

...with some "hammer blow effect" (don't know if this is the correct term in English)
18650_Mounting_System_16s100p_28.jpg

state of yesterday evening, now the parts will have to dry and after christmas it will going on
18650_Mounting_System_16s100p_29.jpg
 
Last edited:

Stefanseiner

Member
Joined
Apr 16, 2020
Messages
128
in the meantime the mounting system is done and installed
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_065.jpg

time to build the packs.
It's a recycling of the "bad" cells between 1.500mAh and 1.900mAh
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_066.jpg

the good ones above 2.000mAh are sorted in 50mAh parts, this are only sorted in 100mAh ones. But I think that in the planned 100p packs they will level out
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_070.jpg

IR of every singel cell checked
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_067.jpg

this is the part of the building process I like the most :cool:
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_074.jpg

very satisfying to complete the packs with cells which got so much time to prepare
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_076.jpg

the side you will see with red Sanyos
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_079.jpg

put the top cover on...
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_081.jpg

sits and fits :)
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_083.jpg

very nice to fill the mounting system with akkupacks
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_084.jpg

just slide in and that's it
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_085.jpg

KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_086.jpg

On the right side there is a MPPT charge controller (JN-MPPT-Mini 30A) and a grid inverter with limiter which is connected directly to the wallbox so the battery will not feed into the house but only into the electric car I will get within the next few days. Besides the inverter there is the surge protection box (AC and DC), and then the wallbox.
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_087.jpg

KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_088.jpg

KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_091.jpg

next step are the busbars and fuses
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_097.jpg


KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_098.jpg

The busbars are made of 3x 2.5mm² copper wire and a SC16-6 (16mm²) ringterminal at the ends.
The load on the packs will be limited to 20A
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_100.jpg

terminals at opposite ends because of the length of the 100p packs
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_101.jpg

I am using fuse wire (0.2mm / 5amps) at both side. I know one side would be enough but for me it's the easiest and fastest way to connect cells and busbar to use this fusewire
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_102.jpg
 

Stefanseiner

Member
Joined
Apr 16, 2020
Messages
128
I solder the fuse wires to the cells with a cheap solder-station from eBay. For me 370°C on the positive side and 390°C on the negative side seems to be perfect. At low temperatures about zero degrees at my garage where I am working you can add 5°C for soldering better
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_106.jpg

to solder the fusewire to the busbars I am using a 150W iron from Ersa, the 150S. I tried two cheap chinese irons but the tipp will melt faster than a candle and hinders me all the way in my working progress.
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_107.jpg

as solder wire I am using one with Sn60% Pb40% with fluxcore. Works very well without any cold soldering points. I need not more then 1 second per solder point at the cells and 2 seconds at the busbars.
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_108.jpg

here is a horrible boring video but without timelaps you can have a look at the working speed

KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_110.jpg

after finishing the packs I charge them up to 4,05V...
KW52_DIY_Tesla-Powerwall_16s100p_Mounting_System_111.jpg

...and test the real capacity between 4.05V and 3,30V with the modified DL24 electronic load at a discharge current of 15A.
The all have about 500Wh
1610521166743.jpeg

to complete the installation I build some little BMS-holder
KW53_Aiways_U5_DIY_Tesla-Powerwall_16s100p_1.jpg

because I build up two powerwalls in parallel I am using two BMS. This is the small one with 60A/120A max and integrated active balancer with 0,6A balancing current.
KW53_Aiways_U5_DIY_Tesla-Powerwall_16s100p_2.jpg

the bigger, black one on the left can handle 150A/300A with 2A balancing current
KW53_Aiways_U5_DIY_Tesla-Powerwall_16s100p_4.jpg

some connector-plates
KW53_Aiways_U5_DIY_Tesla-Powerwall_16s100p_3.jpg

now it is nearly done. The two banks on the left are one system with 8KWh and the one on the right is another 16s50p system with...
KW53_Aiways_U5_DIY_Tesla-Powerwall_16s100p_5.jpg

...I build as a devided pack-design to get the same size as the first powerwall
KW01_DIY_18650_Powerwall_verkabeln_035.jpg

KW53_Aiways_U5_DIY_Tesla-Powerwall_16s100p_6.jpg

KW53_Aiways_U5_DIY_Tesla-Powerwall_16s100p_7.jpg

then, the last days in the old year I got my new car I am waiting for several month. It's an
Aiways U5 full electric car with 150KW engine and 63KWh battery (good for a range of 400KM)
KW53_Aiways_U5_DIY_Tesla-Powerwall_16s100p_23.jpg

KW53_Aiways_U5_DIY_Tesla-Powerwall_16s100p_33.jpg

KW53_Aiways_U5_DIY_Tesla-Powerwall_16s100p_34.jpg

with a total of 8 cameras and all electronic assistance systems you can get this time including autonomous driving
KW53_Aiways_U5_DIY_Tesla-Powerwall_16s100p_45.jpg

Because I do shift work I can't always charge directly at my photovoltaic and so with the powerwall this should save a lot of money.
btw: electric prices in Germany are the highest in the whole world with 0,39USD per KWh
 
Last edited:

Stefanseiner

Member
Joined
Apr 16, 2020
Messages
128
after this side project at the garage I can go on with my "main" project


the plan:
-> the smaller powerwall at the Infinisolar E 5.5KW will move into the left locker (2x 14s60p with a total of 11KWh in summary)
-> the powerwall with the bigger 120p packs will move to the locker on the right (2x 14s120p with 27KWh)

phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_001.jpg


both locker only have one compartement so I have to add some more shelfs
because it's my first time of welding thin 2mm metal I have to practice a little at some remnants
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_002.jpg


after a while I found the perfect settings, but it's a very slow scope
btw: my first welding tries in general are from last spring as I repaired an old traktor with some 6mm and 10mm steel...
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_003.jpg


to get a good contact for welding I grind two stripes in the inner locker
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_004.jpg


this are the shelfs, 2mm steel too
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_005.jpg


some markings
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_006.jpg


but stop, befor welding I should put the rockwool to the back of the locker first, would be easier then after the shelfs are insered
it's rockwool in 40mm with WLG032 and fireproof higher than 1.000°C
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_007.jpg


no I can weld the shelfs
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_008.jpg


some welding magnets as little helper
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_009.jpg


nevertheless there is not much space for working it works well - but I don't think I will get a design award for my welding skills 😏
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_014.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_010.jpg


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phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_015.jpg


redy done
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_013.jpg


then the locker have to move from the garage, around the house, through the granary into the old pigsty where the inverter is installed
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_016.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_017.jpg


last thing to do for the first day: painting
to be honest - I don't like the color because it's very shiny. But I've done a mistake with the order, I wanted black metal protection paint with some hammer blow effect - and this is without. But in the end it's no big thing, the locker stands in the pigsy and important is that it's some metal protection painting.
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_018.jpg


the next day I will continue with the fireproof insulation
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_019.jpg
 

Stefanseiner

Member
Joined
Apr 16, 2020
Messages
128
all walls will be insulated with the Isover UKF 40mm WLG032 rockwool
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_020.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_021.jpg


for testing the space use a 60p pack of heaters
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_022.jpg


all metal surfaces will be covered with fermacel 10mm plates
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_023.jpg


Fermacell is fireproof over 1.000°C too
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_024.jpg


time for the powerwall to move from the box to the locker
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_025.jpg


this are 4,3KWh in 840 cells
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_026.jpg


disasseble and prepare the packs
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_027.jpg


between each pack I put a Fermacel spacer
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_028.jpg


simply cut with the cutter knife and bend over a edge
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_029.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_030.jpg


there is not much space in the locker - the spacer are too high so I have to cut them down, but 1 or 2 cm are too less for the cutter knife, so I will use the band saw. I guess the saw band will be dull very fast but...
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_031.jpg


...that's the original OEM band and it is not very good and I wanted to exchange it anyway
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_032.jpg


very tight but space enough for 6 packs
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_033.jpg


on this picture you can't see it, but actual I hace a fermacell plate on the top of all akkupack rows to prevent a fire can jump from one pack to a neighbour
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_034.jpg


16mm² cable for the packs
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_035.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_036.jpg


I am using M6 screws to attach the packs directly
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_037.jpg


the second powerwall is at the garden shed
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_038.jpg


on the right side it's a little powerwall I build up for my mother with 3,3KWh, it's just connected for testing. Left is the bigger one with 6,8 KWh
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_039.jpg
 

Stefanseiner

Member
Joined
Apr 16, 2020
Messages
128
the boxes are with fire proof insulation too and it helps to get them a little warmer in winter too (16,3°C and 48,1V)
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_040.jpg


18,9°C at the bigger one
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_041.jpg


the other 14s60p system will move into the locker too
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_042.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_043.jpg


disassambling
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_045.jpg


with the second powerwall I go from the bottom to the top so the both positive poles will meet at the middle of the locker
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_044.jpg


looks bigger in reality
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_046.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_047.jpg


all packs are numbered. The voltage meters are dead because of the low voltage below 3,0V
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_048.jpg


here is the middle
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_049.jpg


ready attached
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_050.jpg


a little additional workaround at the inverter. First I did not think about the system could be crowing and so I only used one pair of cables with 16mm² for one powerwall.
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_051.jpg


Now I add another pair of 16mm²
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_052.jpg


two double-circuit breakers for DC with 63A each (in fact 4x 63A so positive and negatice wire has singel protection)
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_053.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_054.jpg


cable entries
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_055.jpg


im oberen Fach (orig. Zwischenboden) ist nun genug Platz für BMS, Kabel, Schalter etc.pp.
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_056.jpg


at the end both powerwalls are connected in parallel at the inverter, but they get their own bms
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_057.jpg


for mounting the bms I build a little basis
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_058.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_059.jpg
 

Stefanseiner

Member
Joined
Apr 16, 2020
Messages
128
with some hinges to use the space into the locker best
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_060.jpg


some holder for the bms
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_061.jpg


by the way this are "JKBMS" with integrated active balancer and bluetooth app
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_062.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_063.jpg


I glue some nuts at the bottom for better ventilation
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_064.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_065.jpg


on top of the middle plate on the right there is the negative for both bms which goes to the inverter, on the left will be the positive
in front there are the both separate negatives which goes to the powerwalls
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_066.jpg


all parts from the "old" powerwall box will be reused
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_067.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_068.jpg


the two cells are needed to start up the bms
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_069.jpg


the little pcb is a DC-DC converter
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_070.jpg


the JKBMS have a data connection, and with this external dongle they provide a Canbus / RS485 signal
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_071.jpg


the RS485-signal oes via "Modbus-over-Ethernet-Adapter" into the house network so lateron I can monitor all the values from different BMS over one grafic interface
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_072.jpg


the DC-DC converter with 12V is for a voltmeter / ampmeter / thermometer I will add later on the outside of the locker so I can check the status very quick and without some monitoring app
and another DC-DC-converter with 5V for the Modbus-to-Ethernet Adapter
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_073.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_074.jpg


therefor I am using hinges, now there is a little more space in the middle
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_075.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_076.jpg


in the meantime I changed the bms to the same model, the JKBMS BD6A17S-6P with 0,6A balancing current, 13S to 17S, 60A / 120A max. = round about 60 USD
actually I wanted to use the bigger BMS with 150A/300A and 2A balancing current for the bigger 6,8KW powerwall, but then I noticed that this model (the old revision) has no data connection
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_077.jpg


and so I am using identical models with data connection
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_078.jpg


positive wire for both packs
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_079.jpg
 

Stefanseiner

Member
Joined
Apr 16, 2020
Messages
128
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_080.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_082.jpg


minus from each bms to a separate powerwall
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_084.jpg


before I connect the balancer wires I prepare the other locker compartments
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_085.jpg


the three compartments will be mostly identically and all will need 5V
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_086.jpg


this is the part for the middle compartment. Difference here: two little network switches to connect 6 bms over their modbus adapter to the network
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_087.jpg


at the end there will be just one networl cable leaving the locker
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_088.jpg


the switches are working with usb, but I connected them to the 5V DC-DC-converter too
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_089.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_090.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_091.jpg


fits
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_092.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_093.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_094.jpg


just drilling some more extra holes to be able to connect the three compartments
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_095.jpg


this is a real fiddling - balancer cables
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_096.jpg


I solder crocodile clamps on each balancing wire so I can take a akkupack easy out of the locker for service
"3 / 4" means -> goes between akkupack no. 3 and no. 4
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_097.jpg


I hate tangled cord...
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_098.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_099.jpg


phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_100.jpg


... and I love zip ties :)
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_101.jpg
 

Stefanseiner

Member
Joined
Apr 16, 2020
Messages
128
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_102.jpg


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after an hour at the charger the voltmeters are back in life
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_106.jpg


then the balancer connections of the lower powerwall
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_107.jpg


just more fiddling because all wires have to be extended
phoca_thumb_l_KW04_DIY_18650_Powerwall_Spind1_108.jpg


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time to connect both powerwalls together, but the voltages are not the same. no. 1 has 51,25V
Screenshot_20210131-114046.png


and no. 2 has 47,76V
I would not recommend just connecting to wires together with hands because there will be a huge spark in the moment of contact
Screenshot_20210131-135938.png


but in this case all is already wired together and I just have to activate the throughput via the bluetooth app of the bms. When you start them they automatically go into a safe mode and deactivate charging and discharging and you can change these settings manually.
Here you can see that round about 30 amps goe from pack 1 to pack 2, thats about 1.500 watts
Screenshot_20210131-140007.png


akku 2 soaks the 30 amps up
30A are no problem, the bms are good for 60A current and 120A max, as well as the 60p akkupacks
Screenshot_20210131-140033.png



that's it so far.

I hope I can finish my project in February because I have lots of plans and projects I want to do in my garden this year and therefor I will not have time left for the 18650 project
 
Last edited:

Stefanseiner

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Apr 16, 2020
Messages
128
before the next step starts here a video of the actual project status (you may activate subtitels)



disassebling the last few ebike battery packs
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Bild von DIY 18650 Powerwall solarakku laptopakkus recycling batterie




their are all chinese OEM cells from FST, BAK or noname
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Bild von DIY 18650 Powerwall solarakku laptopakkus recycling batterie



disassebling of most of them is horrible because their are glued together
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Bild von DIY 18650 Powerwall solarakku laptopakkus recycling batterie



50% of the cell covers are hardly damaged so I have to renew them later
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altough it's a good deal because most of the cells are quiet new ones with 2.700mAh with an BMS failure and full capacity
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about 300 cells are "naked"
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this is the first time I try some magnets to fix the batteries
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thanks at Pete for this tip
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Bild von DIY 18650 Powerwall solarakku laptopakkus recycling batterie




Bild von DIY 18650 Powerwall solarakku laptopakkus recycling batterie




works a lot better then with washers I used befor the magnets
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todo: capacity testing

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while testing the cells in the background I start to prepare the second locker for the second powerwall
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I bought this for 25 EUR / 30 USD from an fitness studio
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like the other locker too I will use fireproof rockwool insulation at all outside walls
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Stefanseiner

Member
Joined
Apr 16, 2020
Messages
128
40mm / WLG 0,32 / fire proof 1.000°C and above
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Bild von DIY 18650 Powerwall solarakku laptopakkus recycling batterie




preparing for welding
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the shelfs are 300 x 300mm
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after 2,5 hours of welding and grinding it's done. One compartment for one 14s-system.
I have two systems reday-build, so place left for two others if the capacity will not be enough
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but at this point I have to wait for better weather to geht the locker down the muddy way to the garden shed

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when the locker is at it's place I will begin to build in the components
 

Stefanseiner

Member
Joined
Apr 16, 2020
Messages
128
despite it's -8°C work goes on.
Sanding the locker for new painting
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some holes for the 35mm² copper wires
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black metal protection paint
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while the paint is drying I prepare the inner parts
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10mm fermacel plates
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in the meantime the saw band is very dull
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finished. This are all parts for the shelf bottoms, walls, covers and for separators between the battery packs.
together round about 50KG
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so the inlays are ready but the paint is still wet, so I process some more cells.
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these cell holders are already stucked together and numbered
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when finished this will be another
2x 14s60p for the first locker (photovoltaic on the wood storage)
1x 14s120p for the second locker (photovoltaic on the garden shed
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3.360 batteries needed
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some of them are really good ones
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ready - go
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I try to build the visable sides in green
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the mixed batteries are for the inner space
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Stefanseiner

Member
Joined
Apr 16, 2020
Messages
128
for those who lost overview what's going on in capacity:
  • actual there are 50KWh read to use
  • 11 KWh in the old pigsty at the Infinisolar E 5.5KW with 2,8KWp on the wood storage
  • 27 KWh for the garden shed at the MPP Solar MPI 10k with 9,3KWp on the roof of garden shed. The battery packs are not connected in the locker but already build
  • 12 KWh at the garage to supply the charger of the electric car. No photovoltaic at this time, will follow in march / april, planned are 2,8KWp
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until end of this month I will add:
  • 2x 5KWh to the pigsty
  • 1x 10 KWh to the garden shed
  • in sum 70 KWh which will go for this summer seasson
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this are the smaller 60p packs
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on the right the bigger 120p packs
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add the top cover
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ready for soldering
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the the paint of the locker is dry and the way from the house down to the garden shed too so time to move the locker.
But first I need some more space where the barbecue-firewood is stored
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I got some help to move the big locker
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I did not believed in it but we made it without accidents :)
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new place for the locker
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Stefanseiner

Member
Joined
Apr 16, 2020
Messages
128
then carrying all the parts to the locker
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equipping the shelfs and walls with the prepared fermacel plates
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next step: carrying the battery packs. Six at the same time = 30 KG and 6 KWh
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bank no. 1 is already moved into the locker
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next 14 packs will follow
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this are two banks, each consists of 14x 120p and 13,5KWh
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because I made the busbars with two ring terminals I can't mount two packs together directly so I will try a thing
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this is a copper pipe with 6,3mm inner diameter. Just fitting for the M6 screw to improve the conductivity and to fill the gap between two packs
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cutting the pipe in 20mm pieces
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deburring with the round file
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this is how it looks now
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this is the status from the last weekend
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next week I will add the wires, bms and so on.
 

Stefanseiner

Member
Joined
Apr 16, 2020
Messages
128
does anybody know a MPPT charge controller with battery voltage range 52 - 65V or floating voltage 65V?

I am getting my 16s100p system at the garage finished today and recognized that my JN-MPPT-Mini 30A charge controller is able to set the float voltage to a max of 100V (I set it to 65,0V) but it seems that the charge controller ignores this high setting because effective maximum charge voltage is 56,7V - which is shown at the display when running too.
So I have to find an MPPT with 65V charging voltage or reduce the battery system to a 14s which will cost me 2KWh of capacity
 
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Stefanseiner

Member
Joined
Apr 16, 2020
Messages
128
after some research I only found two charge controllers which will fit the 65V.
- MakeskyBlue v118 and v119 (maybe the clone from PowMr can do as well) -> round about 160USD for the 60A version
- EPever Tracer AN series -> round about 300USD for the 6415AN = 60A version

Last weekend I found on eBay a 6415AN as customer return with full warranty for 100USD and so I bought this (and just selled the two "old" charge controller for about 80USD each :) )
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yesterday I installed the EPever. For this I had to do some modifications at the cables at the wall because the EPever is much bigger
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now the batteries can for the first time be fully charged
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to access all parameter of the EPever you'll need the additional MT50 Display (round about 18 USD).
And now the system is running in my preferred voltage range from 52,8V to 65V which is single cell voltage 3,30V to 4,05V
IMG_20210320_124724_3.jpg


and I added a voltmeter with shunt to the system so I can see what's going on with the batteries without connecting to the bluetooth app first. It's at the exakt position where I look first when I leave my car when coming home.
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Now the garage is ready and I can charge the car with the sun :)
 
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