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Hello From Westbrook, Maine
#1
Hello all;

My Name is Wolfgang and I found out about this message board through youtube and google just by typing in 18650 Smile.

I started my solar project with 3 Deep cycle marine batteries and a 45 watt harbour freight solar charge kit. After i ran my AC unit for 3 hrs full boar with a cheap modified 3000 watt 12 volt inverter i was hooked. The process continued with 4 100 watt harbour freight kits for a total of 16 panels and an updated PWM controller. This soon turned into a 48 volt system with MPPT controller and 12 deep cycle marine batteries for a nominal 48 volt system. Then the solar bug really hit me. 12 250 watt panels and more MPPT controllers 8000 watt pure sine wave inverter, grid tie inverter, Battery balancing units chargers specific gravity meters etc. I was a flooded cell guru by the time i was done. Maintaining the flooded cells was a challenge though. Bulk, absorption, float and balancing charging and just plain old maintenance of the flooded cells was aggravating, dialing in the MPPT controllers for all the scenarios and at the end of the solar day making sure my batteries where at least 90% so they would not sulfate. I was looking for a different solution. So AGM, Edison batteries ,Lithium Ion etc. came to mind. Wow did I just step into an enlightenment in battery technology and price. So I turned as most of us do to google and youtube to look at what other people are doing. Again more enlightenment. My background has always been electronics and mechanics. Played with Heathkits, Radio Shack 200 in 1 kits and erector sets when I was growing up and ended up being an automotive technician for 25 years, till I studied computer networking and am a systems engineer at present. Enough about me. So 18650 came up as a very viable and lower maintenance solution. Lord knows how many of these "good laptop batteries" I have tossed.  Sad

So I did what Average Joe and DIYPowerwall said on how to collect cells and wella almost everyone was extremely receptive to the recycling used laptop batteries for my solar power project. The only ones that didn't like the idea of me collecting used cells where the snobby independent Apple repair facilities. All in all though all the independent PC repair facilities where more than happy to help. I also instructed all my friends ( all 2 of them ) no just kidding to ask their local transfer stations to keep an eye out for laptop and power tool packs.
Also Several battery recycling places and 1 major recycling facility are supplying me with the raw materials. So i have a steady stream of 18650s coming in and that only took about a week of footwork and word of mouth. So far so good. Now what? Ah breaking apart the cells. Gloves, strong wrists, and a pair of channel locks and after about 100 or so packs I had the system down. I can now field strip most battery packs in less than 30 seconds not saying that there are some that are damned tough. OK what's next. More you tube. Ah Voltage check and sort. OK Home depot containers 3V+ here, less than 3V but more that 2.5V here, and the rest here. The really dead ones go here so 4 containers. Plus the plastic and the charge controllers and nickle strips in their separate containers. OK That done, now what? More you tubing. Charging and testing. I see. I will post more details and pictures of my charging station build in the appropriate forum. Thanks for reading and remember if 18 X 650 =2000 mAh than life is good. Picture of my System with flooded cells at preset attached.

Later 

Wolf

PS I will update my profile info as soon as I figure it out how and to think I work on networks and computers. Sheees
Arbalast and hbpowerwall like this post
If 18 X 650 = 2200+mAh then we have power! 
May all your Cells have an IR of 60mΩ or below Smile
Last count as of 2/16/2019
Total Number of Cells           2206
Cells  >80% of Capacity        1506
Cells <79% of Capacity         666
Cells >2200mAh & ≥ 80%    1082
Google Drive for info https://drive.google.com/drive/folders/1...sp=sharing
Not your average Wolf       
            Cool



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#2
Welcome and impressive system. glad to see someone else who like breaking apart cells. I find it relaxing! Mind going over the flow of that System you posted? looks very nice and What inverters are you running?
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#3
(10-09-2018, 02:39 PM)jdeadman Wrote: Welcome and impressive system.  glad to see someone else who like breaking apart cells.  I find it relaxing!   Mind going over the flow of that System you posted?  looks very nice  and What inverters are you running?

 Thank you jdeadman

I am using a GTIL2 and a Power Jack 8000 a proverbial thorn in my side. But that's another story.
I just posted my GTIL system on "Solar Panels, Charge Controllers, and Inverters" and have all the info there.
Here is the wiring diagram of my complete system. let me know what you think. I have also added it as a full size attachment.




Wolf


Attached Files Thumbnail(s)
   
If 18 X 650 = 2200+mAh then we have power! 
May all your Cells have an IR of 60mΩ or below Smile
Last count as of 2/16/2019
Total Number of Cells           2206
Cells  >80% of Capacity        1506
Cells <79% of Capacity         666
Cells >2200mAh & ≥ 80%    1082
Google Drive for info https://drive.google.com/drive/folders/1...sp=sharing
Not your average Wolf       
            Cool



Reply
#4
Cool. Very nice. What's the Story on the Power Jack?
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#5
(10-09-2018, 04:59 PM)jdeadman Wrote: Cool.  Very nice.  What's the Story on the Power Jack?

You had to ask.
OK I orderd this unit https://www.ebay.com/itm/15000w-LF-PSW-S...4b2d61bbe0

The first one arrived and was so heavily damaged I had to send it back. Literally wires had come un-done the transformer support was all bent and it was in terrible shape.
I got the replacement unit and it looked let's just say okay. Cosmetically it looked good and I was happy. I wired it up and did some testing with my heat gun and it was working.
I built a proper support bench and wired it into my system. Turned it on with no load on it and about 5 min into it there was a lot of popping and sparks and smoke 
24 of the MOSFETs had given up the ghost.
Contacted the seller and they sent out all the new MOSFET boards (8) for a total of 48 mosfets. Replaced those which was a treat with my big hands especially next to the transformer. Turned it on and nothing. Investigated and found that the MOSFET driver board had also blown.
.
Got that replacement and finally something made the right noises but no power and it would not shut off. Traced that to 2 popped capacitors on the Power source board (sorry no picture). Got a replacement for that. In the meantime I figured I might as well order all the boards from powerjack direct and pay for them as if this thing is so sensitive and I'm in a jamb I might as well stock the replacement parts. OK so they came from a slow boat finally and of course I have a version 4 main IC board and they sent me a version 3.72. Another email chain back and forth that would have been the envy of rapunzel. but I digress. The inverter finally powered up and was humming along with the warranty replacement parts and producing a satisfactory 240 volts. I threw the main breaker to the grid off and turned the inverter breaker on and lo and behold my house was up and running on the inverter. Good stuff. I obviously have all the sensors available in the shed and the house and I was drawing about 20 amps out of my battery bank and everything was humming along just fine. I was happy. As this was not an emergency and the grid was up and my GTIL was basically cutting my electric bill in half I rescinded to just using this inverter for emergencies as my calculations turned out to be that I would kill my battery bank in about 5 to 6 hrs. Still not bad for an emergency and it would probably last longer if I am conservative with my emergency power use.
Well my battery banks specific gravity per cell was approaching a not so good level and after reading as much chinese-english as I could I determined to try the battery charging feature of this inverter. So I powerd everything up and switched the ATS switch to UPS lo and behold the inverter started charging my batteries at 60 amps. Cool.
Then my 20 amp 110 breaker clicked off. I was pulling too much current to charge my batteries. Hm okay so another run to home depot. 30 amp 110 breaker box and 10 gage wire
etc. Tried it again that worked no more tripping the breaker. about 5 min into that test Pop one of the charge controller relays let go.

So I called that a fail.
Luckily I had another board that I ordered on my dime and replaced it and it is now working again. in the meantime I am waiting for a replacement charge controller board and the version 4 main IC board. As of yet I have not put the cover bolts back on.
That's the story.

Wolf
If 18 X 650 = 2200+mAh then we have power! 
May all your Cells have an IR of 60mΩ or below Smile
Last count as of 2/16/2019
Total Number of Cells           2206
Cells  >80% of Capacity        1506
Cells <79% of Capacity         666
Cells >2200mAh & ≥ 80%    1082
Google Drive for info https://drive.google.com/drive/folders/1...sp=sharing
Not your average Wolf       
            Cool



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#6
Hey Smile
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#7
Wow Talk about playing the long game. Dude that's crazy. Right now I've only been playing with UPS units and they have been good so far just not great in the Wattage department
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#8
Greetings! Great setup. Just curious where did you get that equalizer from?
Reply
#9
(10-10-2018, 12:42 AM)Geek Wrote: Greetings! Great setup. Just curious where did you get that equalizer from?

I built it.
Using  (3) 48V Solar System Battery Balancer Equalizer For Lead-acid Batteries HA02, a uxcell 12.6"x9.5"x2.3"(320mmx240mmx60mm) ABS Junction Box Universal Electric Project Enclosure and (3) MakerFocus 4pcs Digital Voltmeter 0.56 Inch Waterproof and Dustproof Two-Wires DC 2.5-30V Digital Display Voltmeter, Reverse Polarity Protection and Accurate Pressure Measurement 4 Colours. 16 gauge color coordinated wire to coordinate with the Leds.


Wolf
Geek likes this post
If 18 X 650 = 2200+mAh then we have power! 
May all your Cells have an IR of 60mΩ or below Smile
Last count as of 2/16/2019
Total Number of Cells           2206
Cells  >80% of Capacity        1506
Cells <79% of Capacity         666
Cells >2200mAh & ≥ 80%    1082
Google Drive for info https://drive.google.com/drive/folders/1...sp=sharing
Not your average Wolf       
            Cool



Reply
#10
I like your setup.
How long have you been using the MakeSkyBlue chargers, and have you had any issues with them?
I want to use one but I'm worried about my BMS disconnecting (and possibly reconnecting) my battery while it's still getting solar input, if any cells become over-charged/discharged, I don't suppose you've tried it?
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