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Ford energi powerwall
#1
Over the summer I switched from working on an 18650 powerwall to one with EV batteries.  In looking for packs that could be broken down to one or two cells I found the Ford Fusion Energi and C-Max Energi packs that came 25Ah cells, so I bought three of those and got to work tearing them down:







There's four packs inside and a few disconnects to get it down from the 310v 'I keel you!' level.  On the left is the BMS which interconnects the busses in a way that those wires have to be cut or remove two busses at a time to fully get that wiring out of the way.  Also buried in that area are a couple main wires to disconnect.  On the right is a solid metal bar connecting the backs (the top two are connected as a pair and the bottom two are a pair).  Then in the middle of each pack there's a black cover with a disconnect to split the pack in half.









Just when you thought getting to a single pack took a lot of unbolting, there's more!  Each pack is 21s1p with a plastic cover that has metal plates for the bus bar that's held down by 42 nuts and includes BMS wires for each cell plus three temp sensors.  No cell-level fusing.







Now that we have a single pack without a bus bar it'll come apart quickly right?  Well there's a plate on each end, four metal pieces holding them together, six braces, and plastic spacers between each cell.  I don't know how much compression there was when they were assembled new, but at 50-60k miles, some cells bulge slightly and have a lot of tension. 






I came up with a process of putting a board underneath so the cells don't drop, removing the braces, running a strap around the whole thing, removing the top metal pieces, pushing one end of the bottom pieces out temporarily (the cells sit on them), then releasing the strap and removing one end plate.








After all that it's time to sit back and relax and take a good look at the fruits of half a days labor!


Korishan, Redpacket, OffGridInTheCity And 5 others like this post
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#2
Your pile of nuts is impressive Tongue
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#3
Very cool!
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#4
Are you going to test those cells or just take a go at it?

Nice work.
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#5
I set up one 7s3p pack from each Ford battery to rotate out and test all the cells with an iCharger x8 that'll let me do regenerative discharging during the tests:


I've been charging them as needed with a couple 245W panels


To limit the tests I've done them in batches of 7, figuring if any batch is too far off from others in the pack, I'll test individual cells then.
100kwh-hunter likes this post
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#6
If you use the image upload here within the forum your photos will be indexed in google & show up in the images galleries.

Those iChargers rock, the regen function is awesome!
Save 10% at Battery Hookup with code 'Powerwalls' Just enter it in checkout www.batteryhookup.com
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#7
(11-19-2019, 03:06 AM)hbpowerwall Wrote: If you use the image upload here within the forum your photos will be indexed in google & show up in the images galleries.

Done!
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#8
I got some ends in and shortened up the wiring:


And while it was sitting there, why not do a little testing?  Battery-powered fridge:


It has 6ga and 120A connectors from UPS battery packs I got from work when we de-commissioned a server room.  Just need to create 9 more and wire up BMS connectors for them.   Obligatory hoard box pic:
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#9
I picked up a 24U server rack to house everything including a 48v APC 3000 UPS that I got for free from work.  With two charged 7s batteries, it was time for another test but first I decided to make some hot chocolate:

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