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Wobbleszo Powerwall
#1
Hello Second Life Storage, 

I wanted to post my project here. The current state is a WIP and to simplify things I have simply been posting updates to my Google site (https://sites.google.com/view/wobbleszo/home). I don't have any ads or anything to make revenue (mostly just share my progress with family and friends). 


To Do List: 

  1. Build new 14s, 200p 300p pack from the 3200mAh cells Panasonic NCR 18650BD (using fuse wire this time)
  2. Mount remaining solar panels for better charging (8x 150W Mighty Max and 28x Renogy 100W panels)...they are all on the roof and wired, but need actual mounting
  3. Keep re-wrapping cells and breaking down packs, 1700 more added that need to be rewrapped
  4. Reinstall disconnects
  5. Upgrade Sunkko 709AD+ spot welder pen to one like Mike N or Average Joe did (very nice!)
  6. disassemble ~65 x 36V hover board packs 20 cells each (10s, 2p)
  7. disassemble 14s, 60p battery
  8. construct second 14s, 200p pack from mixed cells
High level information: 
  • 2x MakeSkyBlue 60A Charge controllers 
  • 1x Aims 10kW pure sine wave inverter
  • 6,000+ cells (~4000+ Panasonic NCR 18650BD)
  • 8 gauge cable used for panel to charge controller
  • 4/0 used to connect battery to Inverter
  • 1x batrium BMS v4 kit used with 14 Longmons
  • 4 gauge solid wire to be used for the busbars

I'm sure I am forgetting something, but that is why there's an edit button! 




Edited 04.28.2019 for update of details and progress (plus added one photo).
shonalex, PaulDane, Shade And 5 others like this post

My build is updated regularly on my site:
https://sites.google.com/view/wobbleszo/home
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#2
Great potential there.

That one photo of the 36v system isn't for the OCD crowd. :-)
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#3
(12-04-2018, 11:55 PM)Shade Wrote: Great potential there.  

That one photo of the 36v system isn't for the OCD crowd.   :-)

Unfortunately, I do not excel in OCD. I try to do my best to be safe, but I am not one for great cable management or lining everything up just so. I'll keep updating as I make progress; thanks for the comments!

My build is updated regularly on my site:
https://sites.google.com/view/wobbleszo/home
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#4
Sure, for some there is an aspect of OCD and/or a professionalism (see https://www.reddit.com/r/cableporn/), but the main reason that a lot of effort is made to keep the installation neat and tidy is to ensure that it is maintainable (perhaps bu others) and that mistakes are not made. These are safety issues.

In the UK (and I presume other countries) all electrical work must be carried out by a "competent person". Note that the law doesn't prescribe what a competent person is, that is for a court to decide. One favoured method would be for that person to have gained accreditation from a recognised body and have suitable tickets for the work undertaken. However that in itself doesn't prove competency. If you did some work on your house and nothing burned down, it may be hard for a 3rd party to argue against your competency in court, but if it did burn down, you'd probably find it hard to prove the other way.

Fires can happen even if the installation was done perfectly. A faulty piece on equipment perhaps. If you had a fire and there was an investigation you'd likely find yourself uninsured. Someone would look at that installation and immediately come to the conclusion that you are not competent and I think you would find it impossible to argue otherwise. Low voltage DC is not regulated in the same way as Main AC supplies so one can argue that you are competent even without relevant qualifications, but you would need evidence. If you have a well laid out design, documented to show schematic diagrams, along with calculations for fusing, breakers, cable sizes etc, then you would have all that is required to argue on court.
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#5
Wobbleszo: Sorry to tease you about the non-OCD cable management. I didn't mean to be harsh. From the photos, all evidence suggests you enjoy your hobby, which will keep you off the streets at least. <-- you see, I can't help myself.

The 36v system was the one I studied the longest. There's a lot going on there. Still, I say 'potential' because you have a ways to go yet to really power that 10kW split-phase beast of an inverter. Your transfer switch setup is by far the safest way to go on the AC side.

So many cells. I empathize. In my case, I need only remind myself that it's a hobby which means I have infinite time to complete what would otherwise be a daunting task ahead. Do it for the joy of it and that imminent feeling of accomplishment (my personal favorite).
Wobbleszo likes this post
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#6
(12-05-2018, 11:08 PM)Shade Wrote: Wobbleszo: Sorry to tease you about the non-OCD cable management.  I didn't mean to be harsh.  From the photos, all evidence suggests you enjoy your hobby, which will keep you off the streets at least.  <-- you see, I can't help myself.

The 36v system was the one I studied the longest.  There's a lot going on there.  Still, I say 'potential' because you have a ways to go yet to really power that 10kW split-phase beast of an inverter.  Your transfer switch setup is by far the safest way to go on the AC side.

So many cells.  I empathize.  In my case, I need only remind myself that it's a hobby which means I have infinite time to complete what would otherwise be a daunting task ahead.  Do it for the joy of it and that imminent feeling of accomplishment (my personal favorite).

I take no offense to the teasing...cable management for me is always less of a priority than other facets. I want to have everything work and then I might get to making it look pretty. Truthfully, I rarely get back to making it look pretty. For the 36v setup, I was really just trying to get everything connected and see IF it even worked. I tried to route the wires in the best way I could thing of in terms of using the least wire to accomplish what I wanted. with the 10kW inverter, I can power it for about 36 hours with a few small loads using the 14s, 60p. I have tried to be reasonably safe where it made economic sense. I realized afterward that I should have cell level fuses, so I will be doing that for the next 14. I think with the 14s, 200p I should have over 27 kWh to put into service as compared with the 6.5 kWh battery currently in place.
Korishan likes this post

My build is updated regularly on my site:
https://sites.google.com/view/wobbleszo/home
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#7
Why cut the wires short to make them tidy when you "might" need/want to move things and need to get "new" wire lengths. Wink Once everything is pretty much how you want, then you can snippy snip snip to make things cleaner and easier to manage.
Wobbleszo likes this post
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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#8
Over the past few weeks I continued processing work on cells; up to 1000 cells ready for building into new packs. Most of them are the Panasonic NCR18650BD with some LG2600mAh cells thrown in to the mix. I have ~300 cells that need to be re-wrapped and ~700-800 that still need to be processed. I've started looking at inverter fuses/breakers since safety is important, but when I looked at the AIMS manual for the 10kW inverter, it says to use no less than the short circuit protection. I'm having a difficult time finding exactly what that protections should be for the inverter. I tried using several different calculators (padding the 25% safety) and looking for additional information on the AIMS website (as well as searching online, but can't seem to find a good size of fuse/breaker to use. On one site it specifies differing levels of protection for a fuse vs. breaker. The only other person that I know of using the same inverter is Admin Mike, but wasn't 100% sure on using the same fuse from his build.   I'm certainly open to suggestions from those with more experience on battery to inverter protection. 



If you're interested, I continue to update my site with additional details:
https://sites.google.com/view/wobbleszo/home
hbpowerwall and Korishan like this post

My build is updated regularly on my site:
https://sites.google.com/view/wobbleszo/home
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#9
Small update on progress of processing cells: 1680 milestone for 14s, 120p! I still have ~420 cells to process, but only 280 to make it closer to the build phase. I've determined that I'll use the same Blue Sea Systems Class T Fuse like Mike did, but I think I am going to go with the 300A one instead of the 250A one. I was looking at the amperage range and the max with a 1.25 safety buffer was ~288A (3.1V x 14 = 43.4V and 10000W/43.4V = 288.02A) please correct me if I'm wrong here! 

Still need to decide on what to use for busbars, but leaning toward 3 strands of 4AWG grounding wire twisted and crimped, but then I need to figure out what size of crimp end to use to fit both ends into (6 strands of 4AWG). More maths! I appreciate the support of this community and my friends and family through this long process! 


at 1640 

at 1680 
Korishan likes this post

My build is updated regularly on my site:
https://sites.google.com/view/wobbleszo/home
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#10
You really work on an alien space craft, don't you? Look at all those greys!!! Tongue
Wobbleszo likes this post
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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