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Recomendations for fusing and connecting?
#1
Hi together,

I have several e-bike cellblocks which I want to use for my upcoming PW.
Originally they are 36V10S5P and 36V10S6P. I managed to take off the original "busbars" without destroing the cells.
Unfortunately the cellblocks were in bags filled with some kind of black mass that now is everywhere in the gaps between the cells
and therefore I didn't manage to take the cage apart.

   

I now thought about  contacting them in the way, that all 50 cells in one block are in parallel, and then combine 14 of these blocks to 48V....
which makes 14S50P


Now I need some ideas how to add new busbars and fuses to the cellblocks.
So does anyone have a suggestion how to setup the connection and fuses?

Regards

cadric
1. Installed Grid-Tie System 2017 16,5kWp:  55 x 300Wp BenQ, SMA Tripower 15000-TL30 (18-east/17-south/20-south)
2. Building Offgrid System 7,5 kWp: 25 x 300Wp Solarworld (5x( 3S + 2S )), 2x PIP-5048, in process : 18650th Powerwall, Rest TBD
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#2
(01-20-2019, 07:05 PM)cadric Wrote: Hi together,

I have several e-bike cellblocks which I want to use for my upcoming PW.
Originally they are 36V10S5P and 36V10S6P. I managed to take off the original "busbars" without destroing the cells.
Unfortunately the cellblocks were in bags filled with some kind of black mass that now is everywhere in the gaps between the cells
and therefore I didn't manage to take the cage apart.



I now thought about  contacting them in the way, that all 50 cells in one block are in parallel, and then combine 14 of these blocks to 48V....
which makes 14S50P


Now I need some ideas how to add new busbars and fuses to the cellblocks.
So does anyone have a suggestion how to setup the connection and fuses?

Regards

cadric

Hi Cadric,

First of all, Are these packs more or less the same capacity? What do they look like on then other side?

Ciao, Rik
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#3
(01-20-2019, 09:05 PM)RikH Wrote: Hi Cadric,

First of all, Are these packs more or less the same capacity? What do they look like on then other side?

Ciao, Rik

Hi Rik,

on the other side they look the same, like I said, Busbars are off already.
Capacity is around the same on all blocks.#

regards

cadric
1. Installed Grid-Tie System 2017 16,5kWp:  55 x 300Wp BenQ, SMA Tripower 15000-TL30 (18-east/17-south/20-south)
2. Building Offgrid System 7,5 kWp: 25 x 300Wp Solarworld (5x( 3S + 2S )), 2x PIP-5048, in process : 18650th Powerwall, Rest TBD
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#4
What makes this a problem is that they are alternating batches. Trying to change that to a different voltage other than what it was originally built for would prove to be a little difficult.

I was thinking of making some plates that you'd spot weld to certain sets, but in some places the plates would need to overlap, or use jumper wires, to finish it out.

Another option is you could see about going 72V system voltage. Keep the packs as 36V and then put 2 packs in series. Altho, you would need a bms that can handle that higher voltage. As well as an inverter/charger that can as well. I'm not sure what the price differences are for the jump between 48 and 72V
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#5
Hi,

what about connecting each 5P block with thin cable and then combine these cable together on the plus and minus side.
10 cables on each side. And between each cell of on 5P block use fuse wire.

1. Installed Grid-Tie System 2017 16,5kWp:  55 x 300Wp BenQ, SMA Tripower 15000-TL30 (18-east/17-south/20-south)
2. Building Offgrid System 7,5 kWp: 25 x 300Wp Solarworld (5x( 3S + 2S )), 2x PIP-5048, in process : 18650th Powerwall, Rest TBD
Reply
#6
So, after a lot of thinking, and taking in your suggestions I now have a solution suitable for me.

As I have 16 e-bike Akkus atm, which I'm not able to take appart, I found a setup to use them as they are with just some different cabling.

I will combine 3 blocks of 10SXP in series, use the 10S of block 1 and the first 4S of  block 2 and combine them to 14S.
Additionaly when I get more I use the last 4S of block 2 and combine these with the 10S of block 3.
With this I only loose the 2S in the middle of block 2 but get 2 times 14SXP which I can connect in parallel then.
I will start now with the 1st and 2nd  block and connect these 8 times in parallel, which will lead to 14S5P x 8P = 14S40P.
I will also try to add one of the 30A Fuses from the original BMS to each 14S block.

For better understanding I attached a drawing.



Regards


cadric
1. Installed Grid-Tie System 2017 16,5kWp:  55 x 300Wp BenQ, SMA Tripower 15000-TL30 (18-east/17-south/20-south)
2. Building Offgrid System 7,5 kWp: 25 x 300Wp Solarworld (5x( 3S + 2S )), 2x PIP-5048, in process : 18650th Powerwall, Rest TBD
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