18650 Garden-Powerwall with 50KWh in Germany

Stefanseiner

Member
Joined
Apr 16, 2020
Messages
79
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
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first I cut a template which I can use for the plasma cutter
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it's my first work with the playma cutter, so results ar far away from perfect...
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...but much better then with a angle grinder
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this will be the boddom part of the mounting plate
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for the top part I build a second template
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some work left for the angle grinder. Rounding the edges and grinding the metal slag
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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
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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
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sits and fits
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ready for painting
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I am using metal protective paint in anthracite...
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...with some "hammer blow effect" (don't know if this is the correct term in English)
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state of yesterday evening, now the parts will have to dry and after christmas it will going on
18650_Mounting_System_16s100p_29.jpg
 
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Stefanseiner

Member
Joined
Apr 16, 2020
Messages
79
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

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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
79
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

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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
 
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