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the "this sounds like a fun project" powerwall (in Belgium)
#1
Lightbulb 
Hi everyone!

After discovering the youtube channels around june 2017 and this forum shortly after, it's now finally time to show what I've been able to do so far...
I enjoyed the idea of reducing my power costs by going solar, but most of my usage is not during the day so battery storage sounds like the ideal solution.

I started out collecting laptop batteries, but quickly found that a lot of them have quite a number of cycles on them and they'd show only a small capacity remaining.
Since I live near the border of Belgium and The Netherlands, 2 nice flat countries with lots of people using e-bikes, I started doing the rounds at the bicycle shops.
I've collected quite some packs, given away some as well...

I also built sort of a "charger board", mostly because I modded the OPUS chargers with 80mm fans.
It's powered by an old computer power supply and has 12 TP4056's for charging, 4 slots for reviving 0 Volt cells and 3 OPUS C3100's (3 slots have died, unfortunately).
    

After about 1,5 years I managed to gather 2266 cells and a little over 1700 of them are 2000 mAh or more in capacity.
It took a while, at first 1 wanted 80P packs and then a 100P and.... Big Grin  Now I've settled for 60P, but built 28 of them right from the go.
After using repackr, I had the values to go in each pack but some late nights later it seems I've made quite a few errors along the way.
-> ->
So 28 packs on the table, each 136,3 Ah which gives 14 kWh. 
I've also purchased:
  • a MPP Solar PIP-5048GK (the latest edition)
  • an ABB 160A DC breaker (eBay link)
  • 35 mm² cable to go between battery and inverter
  • A Batrium WatchMon4 suite to complement it all
  • solar panels to come when the battery system is operational
I've only completed the packs right now, so I can keep you all updated with the next steps coming up...
Thanks for reading!
WuggyBuggy, Stefaan De Ridder, BlueSwordM And 12 others like this post
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#2
Goeeeee Bezig !!!!!! Big Grin

Good Job!!!!!! Big Grin
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#3
Great start,
I'm looking forward to seeing your build progress.
UK Southwest.

7 kWp Solar Panels (28 x 250Wp Shinetime Mono).
14 X APS YC500i Micro Inverters.
28 X 40P 18650 cell packs/modules configured as 14S 80P.
Sofar Mass Energy ME3000SP AC coupled charger/inverter.
Still sourcing and processing cells for powerwall.
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#4
Good job, looks like you had the mats to actually make complete slots on the custom charger.
Make sure to monitor the PSU voltage, as it can drop quite a lot if you have many bad cells charging in the same time.
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#5
Hi, how did it go with the DC breaker, does it have a shunt trip, does it work ok with batrium watchmon?
Please share your experience with it, since a friend is considering it for his powerwall. Thanks
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#6
Hi Frnandu, I have to admit that I haven't tested it with the Batrium yet (because that isn't set up yet).
The DC breaker has the auxiliary shunt trip, which is rated at 50 VA on 24 to 40 Volts. I have bought a dedicated 60W 24V psu to provide power for it to trip and that works very well.
So depending on the voltage in your powerwall, you could use it directly off 24V, but since I was going for 48V I had to take this side step.
Here's a photo (from the seller):

This is the breaker I've got: ABB Sace TMAX T1D 160 PV 1100V DC 160 A 4-pole circuit breaker
Batteries harvested: 2500+ / Cells tested: 2266 (Average: 2357 mAh)
Usable 1800+ mAh batteries: 1943 (78 %) / Cells in production: 14S 60P -> soon 1680 =14S 2x60P

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#7
(02-07-2019, 11:15 PM)wimpie007 Wrote: Hi Frnandu, I have to admit that I haven't tested it with the Batrium yet (because that isn't set up yet).
The DC breaker has the auxiliary shunt trip, which is rated at 50 VA on 24 to 40 Volts. I have bought a dedicated 60W 24V psu to provide power for it to trip and that works very well.
So depending on the voltage in your powerwall, you could use it directly off 24V, but since I was going for 48V I had to take this side step.
Here's a photo (from the seller):

This is the breaker I've got: ABB Sace TMAX T1D 160 PV 1100V DC 160 A 4-pole circuit breaker

Thanks Wim,

I'm using a ABB S5N 300A for a year now, and the shunt trip it's connected to the middle of my 14s battery (7s should fit the voltage spec of the shunt trip), and relay'ed by the watchmon. Since this is NO and only uses power when triggered, very briefly I consider this to be ok, with no need for external power.

I'm asking about your model for a friend who is searching for a similar breaker.
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#8
(02-08-2019, 12:19 AM)Frnandu Martiński Wrote: ... the shunt trip it's connected to the middle of my 14s battery (7s should fit the voltage spec of the shunt trip), and relay'ed by the watchmon. Since this is NO and only uses power when triggered, very briefly I consider this to be ok, with no need for external power....
Actually, I could have done that as well... Confused Undecided  Well, I might do it that way after all, the 24V power supply was only a few €.

An update then:
Starting with a small facepalm-moment, since I'm watching this great YouTube video from Average Joe again after making all the busbars.
I ended up cutting and stripping about 170 meter (= 185 yards) of 2,5mm² solid copper wire. But I forgot to straighten them out, before twisting them together. So while some look pretty clean, most have a few kinks in them. Oh well, the copper is still there, that's what's most important. Sleepy

So using a mock-up I bent the twisted wire into shape. I chose to come down at an angle, because I plan to stack 2 60P packs on top of each other.

This might be not ideal, but I kind of drove myself into a corner by ordering only 14 longmons and then deciding I was going for 28 (60P) packs instead of the 14 (100P) packs like originally planned.

What's planned for the rest of the weekend? Not too much, since I have to work late shifts. I'm going to re-sleeve some of the cells with a damaged outer wrap/sleeve.
Running through my options of attaching the busbars to the packs (hot glue, cable straps, ...?).
I hope to start soldering on monday, if the weather allows it since I'd rather do this outside.  I'm guessing that will eat up quite some time.
Still left to decide:
  • How to attach the busbars

  • using 1A or 0,5A fuses. I have a 1000 of both of them.
  • Only fusing the Positive connection, or double fusing?
  • Using wood or metal shelves to store the battery packs or rather a metal filing/archive cabinet to keep everything out of sight (might also be easier for adding fire safety measures later)
Your thoughts? Huh
wim likes this post
Batteries harvested: 2500+ / Cells tested: 2266 (Average: 2357 mAh)
Usable 1800+ mAh batteries: 1943 (78 %) / Cells in production: 14S 60P -> soon 1680 =14S 2x60P

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#9
Zip ties (go through the pack)
0,5A (they do pop a bit higher)
Positive only (resistance)
Metal shelves.... a cabinet is even better (more fire resistant than wood)

Have fun Smile
___________________________________
18x 300Wp solar off grid and 10x 180Wp solar tracker grid-tie
10KW 3phase hybrid inverter. 40Kwh 18650 storage (for now)
My setup: https://secondlifestorage.com/t-Instant-powerwall
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#10
Hey (fellow) Wim, I should give you credit for the cabinet idea  Big Grin
I like it a lot because of the safety with kids around and the possibility to install fire suppressing material in it. Still looking into this...
I'm trying to fine one that will fit in the space I have, but that's only about 1m high.
It should also be 1,2m in width if I want to mount the 14S side by side. Proving to be bit of a struggle.
Now leaning towards using an Ikea PS:
Batteries harvested: 2500+ / Cells tested: 2266 (Average: 2357 mAh)
Usable 1800+ mAh batteries: 1943 (78 %) / Cells in production: 14S 60P -> soon 1680 =14S 2x60P

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