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MGPTWEGB Battery Build Tread
#1
This is my Build Tread.

I will post updates here showing my work. 
I started out doing 14S but after talking with others and reviewing my Inverters Specs the battery will be 15S
 

Now I have moved my battery checking and building to the basement.
   

Bus Bars will be started soon …
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#2
Nice testing station!
And many cells you got there. How many cells in parallel? 180?
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#3
Ya  I have 15 packs @ 180 cells each right now in there holders ….   All good..

I have trays of cells 2000 mah...  2100mah... 2200mah and so on but not enough yet to start putting them in the holders as it takes 120 cells to make a row.  
I have another 300 or so cells tested for MAH   but resting to check for discharged.
these 300 or so cells are from 2000 to 2700 mah   
So once these are tested for self-discharge I hope that I can finish my last 3 rows in the cell holders.


But There is still a lot I can do ….
Look at this MESS !
 
Yep    That will be bus bars ….    most of it is 12-2 with ground.

The Yellow is the newer 12-2 and there is some older 12-2 that is white in there... Its all 12-2 and a little 10-3
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#4
Hahah, bad hair day Tongue
Proceed with caution. Knowledge is Power! Literally! Cool 
Knowledge is Power; Absolute Knowledge is Absolutely Shocking!
Certified 18650 Cell Reclamation Technician

Please come join in general chit-chat and randomness at Discord Chat (channels: general, 3d-printing, linux&coding, 18650, humor, ...)
(this chat is not directly affiliated with SecondLifeStorage; VALID email req'd)
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#5
Had some free time today ..So I started doing a HAIR CUT on that dolly 
 
First removed the outer covering ……
 
I did this in my living room. So now I need to go back down stairs and start striping the inter shielding.


And I started my jig to bend the wires....


Here is how I mounted the 12G wire so to get the Kinks Out of the old wire …  Just use a washer head GRK screw to the fire blocking in my basement wall.
 

Once I had them all straight …   I used 3 of them together..  I used a Bassy Clamp on the same fire blocking 2x4 to clamp the 3 wires down.
Then chucked them up in my drill...
 

And here is the bus bar . . . . . ( 15sec of run time in low speed ) bar length in 60 inches.
 

Well    that's it for now !
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#6
still working on bus bars ..
I finished my little gig to bend all my twisted bus bars....
 
Here's a pic of some I did today....
 
And this is how they look setting on of the cell....
I using 3 - 12 g wires to make one bar. But using two bars per side. This way each bar carries 1/2 the cell ( 100 P on each bus bar )

I'll be using a 1/2 thick 1 x 3 inch Copper plate at the ends of the bus bars.    Drilling 4 holes to let them inset into the bar...  them I'm going to braise the bus bars to the copper blocks.
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#7
the work room is getting full  ..  
first group is looking good   .. 
475 POUNDS .. just picked up . . 
 
My first group to be tested . . .out of the last pickup.. 
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#8
Nice work @MGPTWEGB your processing ia sure inspiring me, keep up the neat job ..am learning from you Smile.
BTW my 3s 12V Pack for my power shed went rogue on me .. had the whole pack down to 8V until i check carefully and discovered that my middle pack had a cell shorted ... and with it came down the whole pack. all the cell in the the pack down with it too.
just rebuilt it and to be tested out later in the week.
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#9
(08-22-2019, 10:22 PM)oloyeadeniran Wrote: Nice work @MGPTWEGB your processing ia sure inspiring me, keep up the neat job ..am learning from you Smile.
BTW my 3s 12V Pack for my power shed went rogue on me .. had the whole pack down to 8V until i check carefully and discovered that my middle pack had a cell shorted ... and with it came down the whole pack. all the cell in the the pack down with it too.
just rebuilt it and to be tested out later in the week.
Thanks !!!
I have been working on this for some time now....   Its been fun and hard at the same time.
I have been lucky with finding batteries . . .  I just happen to know the right people in this area . . .
Once you find the source … Keep it up with there battery turn over or they will sell to someone else. Sometimes that is hard 
when you show up and there is 1000 Pounds of Med packs and Laptop packs. I have moved up with my guy … @ one time I had to take ALL THE BATTERIES !
even the NON - 18650 stuff.. Now they just let me go though what they have and pick through it all...

ANYWAY 

So you have a 3S setup ..  How many P is it ???
I thought about 24V but just said nope ….   need to get the voltage up so I don't spend an arm and a leg for cables....
I really wish there were more companies doing HV inverters . . .   they are out there but the cost is just WAY TO HIGH ...

Anyway good luck testing your new replacement pack !!!
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#10
Well its been some time ...
UPDATE TIME !!!!!!!!!!!
I have been working on this for a very long time ….   I'm now getting to the point where I can see the work that has went into this... Here are some pics of me going through the cell that I want to use in my PACKS. I would say these calls have been setting for 7 months to 2 years ….. So I know these are the BEST OF THE BEST. I removed all SONY , ST , SANYO , OR OFF BAND CELLS. I did use SAM , LG , MOLI , PAN cells 
 
This was me going through what I knew was good cells.....   LOL  after all the testing...…... I still found 5 cells that were DEAD !!!  yes dead at .5 volts. this was after they had been checked for discharge after resting of 6 to 7 months. This is why the cells that I have been working on this past year will not be used in this group of batteries....  They need to be checked again after a LONG REST !!! and retested for there total MAH then put back to a storage charge.

Here is a look around the BATTERY ROOM as it is now...  These pics are over a 5 month time frame so things do get moved around a little.....
 
NOW for the BATTERY !!!!!!!!!!!!!!!!!
I did down size the pack from my plans ….  BUT at this point I have to stay with this spec as the packs are going together.. Here are some build pics as I put them together...The PACK will be 152 P   with 8 open bays for TOTAL MAH adjustment if need be. Or if 1 pack down the road needs a cell or 2 just to balance them out to one another.
 
Here are some pics of the wiring on the cells 
3 amp glass fuses with a solid copper NON fused link on the other side. Main bus bars are 3 12ga solid copper wires twisted together ( this was made from 12-2 with ground house wire.
PLEASE NOTE ... I did go back after the first pack was together and add 3 12 ga wire on both sides to make sure the battery bus bars worked together. Some of the pics don't show them but some do. There are 4 twisted pairs coming off of each end that will get a Copper BLOCK that will be used to tie them together and be used to connect the packs together.
 
After the pack was together I used my Power Lab 8 to do a lite discharge and charge ….
 

So far I have 4 packs put together and still testing more cells for the next group....
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