12v 60 cell pack

Wattsup

Wattsup

Member
Joined
Feb 19, 2017
Messages
513
Hi guys
After charging and discharging cells for a while I have 60 mainly samsung 2600 and a few 28s.

All cells were above 2 volts when harvested and over 2000mah capacity on testing.

I'm using 34x5 cell holders to make a 3s 15p pack for powering some fans, lights, chargers in the shed

I have a few questions re wiring, having only made smaller packs.

Q1.Would you wire 3 x 4 volt packs and join them in series?

Q2. Not sure how to physically join/ wire the packs?

Was originally thinking of making the packs able to be seperated for balancing/ charging but dont think I'll bother.
I have an imax b6 so will most likely attach wires for that.

All thoughts and advice welcome
 
Wattsup said:
Q1.Would you wire 3 x 4 volt packs and join them in series?

Q2. Not sure how to physically join/ wire the packs?
Click to expand...

Q.1 ... yes always make packs ofcells in parallelfirst , so you have 3 blocks at 4V ...then put them is serries to make 12volts .. then you can check the voltage of each individual 4V block ...it's important these are 'balanced ' with one another (stay near the same voltage) Don't put all your bestcells in one 4Vblock, the idea is to get the3 blocks all of the same AHr capacity , as best you can.

Q.2 ... need a good soldering iron ...have a look on Youtube someone's probably made something similar , you won't need very thick wire to join the cells 2.5 square mm is about right for the size you're making.

You say... "Was originally thinking of making the packs able to be seperated for balancing/ charging but dont think I'll bother." ...You have to be able to have connections to each of the 3 blocks of cells .... there's no way to avoid this for balancing , which is essential .. all cells will be in one package , but in 3 individual blocks .. so you should have 2 thick wires for 12V , and two thin wires (just for balancing) coming out of the whole thing (the thick wires are also used to ballance) ....Good Luck
 
With 3*15 you only use 45 out of the 60 cells.

I would go for 3s20p :)

Then you make every 20p block one pack and all 3 connected in series. As above answered.
 
daromer said:
With 3*15 you only use 45 out of the 60 cells.

I would go for 3s20p :)

Then you make every 20p block one pack and all 3 connected in series. As above answered.
Click to expand...

Thanks for the helpful replies :)This is a substantial project for me having virtually no electronics experience, so humor me please :cool:

I have grouped the cells and got them very close in capacity.

The cells are tinned , ready to be joined butI have a few questions....

Q1.In the 3rd image below, this is how I was going to wire the cells, is this ok, or is there a better way?

Q2.I like the idea of having cell fuse wire, in case a cell goes bad, in that case how would you recommend I wire the packs and what gauge fuse wire would you recommend I use?

Q3. Would xt60 connector be enough or should I go anderson plug or similar?

I will have balance wires for balancing with the imaxb6 if needed.

Thanks



image_miyiso.jpg

image_nrlpdo.jpg
 
Q1. I dont like that at all. Because you are making the busbar as long as you possible can. I would go 1 line only and just connect them.

Q2. I use 35AWG 5A thinned copper fuse wire. Rated at around 5A. And should work ok for most packs since you arent drawing that much current from each cells anyway.

Q3. If you stay way below 60A yes thats ok. And since you would go for 3s20p i would do xt60 all days. You can also go XT90 that is bigger.

20 cells in parallell is for me max current of 20A.... In worst case 40A..... But laptop cells should be kept at low currents since thats what they are made up to handle.
 
daromer said:
Q1. I dont like that at all. Because you are making the busbar as long as you possible can. I would go 1 line only and just connect them.

Q2. I use 35AWG 5A thinned copper fuse wire. Rated at around 5A. And should work ok for most packs since you arent drawing that much current from each cells anyway.

Q3. If you stay way below 60A yes thats ok. And since you would go for 3s20p i would do xt60 all days. You can also go XT90 that is bigger.

20 cells in parallell is for me max current of 20A.... In worst case 40A..... But laptop cells should be kept at low currents since thats what they are made up to handle.
Click to expand...

Thanks for the helpful advice!
 
Does anyone know where I can source 35 AWG tinned copper fuse wire in Australia?
 
Ebay, Alieexpress or amazon :) Perhaps not in AU but they will ship ;)

Yes, its not the answer you looked for and i do hope someone can answer your question. If not this is the one i bought and you could most likely find cheaper ones closer to you:
http://www.ebay.com/itm/121664920466

Sidenote: There was a thread up either if it was on the forum or Facebook where several links to different suppliers was added. I dont fint it now though... :(
 
daromer said:
Ebay, Alieexpress or amazon :) Perhaps not in AU but they will ship ;)

Yes, its not the answer you looked for and i do hope someone can answer your question. If not this is the one i bought and you could most likely find cheaper ones closer to you:
http://www.ebay.com/itm/121664920466

Sidenote: There was a thread up either if it was on the forum or Facebook where several links to different suppliers was added. I dont fint it now though... :(

Thanks again Daromer.
Did I mention I subbed to your YouTube channel, you have some great content there!

I'll try to get some wire in OZ first.
If anyone wants to sell me a small amount and I'll cover post of course, would be appreciated.
Would really like to get this build up and running.
Click to expand...
 
I went with 8 amp fuse wire I was able to buy. It is 0.29mm diameter.

Positive side done need to get more wire to finish it. Not the prettiest job but better than my original plan :s



image_lpumvd.jpgimage_gzgzfw.jpg
 
Looks very nice!
 
Finished my first decent pack and am quite happy with how it came together actually

Found it very satisfying making something useful out of cells that are considered useless:)

Pack voltages were 4.14 4.18 4.19 after a couple of hours on the imax are now 4.18 4.19 & 4.20

What voltage variation is considered acceptable through the packs?

[image_pkpygn.jpg

image_ybkecm.jpgimage_hksroq.jpgimage_hedpqa.jpg
 
Wattsup said:
I went with 8 amp fuse wire I was able to buy. It is 0.29mm diameter.

Positive side done need to get more wire to finish it. Not the prettiest job but better than my original plan :s



image_lpumvd.jpgimage_gzgzfw.jpg
Click to expand...

That looks nice and neat good job

Wattsup said:
Finished my first decent pack and am quite happy with how it came together actually

Found it very satisfying making something useful out of cells that are considered useless:)

Pack voltages were 4.14 4.18 4.19 after a couple of hours on the imax are now 4.18 4.19 & 4.20

What voltage variation is considered acceptable through the packs?

[image_pkpygn.jpg

image_ybkecm.jpgimage_hksroq.jpgimage_hedpqa.jpg
Click to expand...

Little meters look good green mine are blue ha ha luck of the draw what you get i guess
 
You must log in or register to reply here.
Back
Top