Beginners Guide to Processing 18650 Cells | Cell Database


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My first build 2014
#1
This was my 1st go at a DIY pack. The larger bank is 2300mah cells and is 17 x 10, the two smaller banks are 2600mah cells and are 10 x 15. Gives me right about 12V @ 400Ah. Not a bad first pack. I damaged many of the heat shrink wrappers taking the laptop cells apart so I so even had to buy new heat shrink and wrap a bunch. Then I was going to wrap them all but that was more time than I wanted to spend in addition to the rest of the build. Its still in service today. I've had to swap out a few bad cells but no major rebuilds. 470 cells total.


This is the batch I am testing as we speak. Its going to become a 12V 1000Ah pack. Ill have 6 packs that are 8 x 30 with 2200mah cells (avg) just under 1500 more cells that we can add to the cell counter! (There are about 2000 in the pics but some are unuable) and all the 1400-1900 cells wont go into any builds.

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#2
Nice work

Thats massive packs in terms of 1000Ah Smile
Follow me! >> YouTube / Forum system setup / My webpage  Diy Tech & Repairs

Current: 10kW Mpp Hybrid | 4kW PIP4048 | 2x PCM60x | 83kWh LiFePo4 | 10kWh 14s 18650 |  66*260W Poly
Upcoming: 14S 18650~30kWh | Automatic trip breakers, and alot more
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#3
(07-05-2017, 11:15 AM)daromer Wrote: Nice work

Thats massive packs in terms of 1000Ah Smile

Its big. Edit* Its actually a 12V not 24V, it will be two 12V 500Ah packs in parallel. It was late here of the fireworks last night and I was a bit sleepy.

So I checked out a few of your videos mate, pretty cool. I wish I had done the Opus chargers instead of the Turnigy Quad. I like the Turnigy but Opus are so much easier! I ordered 10 Ardiuno Nano boards that should be here today and I plan to built my own little charging/discharge station with them. If it doesn't work out, I may sell the Turnigy Quad and just buy the Opus anyway.
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#4
Here's a quick shot of the first of six new 8 x 30 ( approx 500Ah ea) packs. It's The 1st time I've tried to use the twisted wire busbar setup. I used 3 x 14AWG wires twisted together, then made two separate runs and tied it all together at the top with a #4 lug.
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#5
That pack looks Great!!! [THUMBS UP SIGN]
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#6
(07-05-2017, 11:15 AM)daromer Wrote: Nice work

Thats massive packs in terms of 1000Ah Smile

I am curious what is the nominal Low voltage cut off  on lithium ion cells...  and what would you advise to set your inverter  to cut off voltage ?

and what safety  method is advise for High voltage disconnect on charging devices  AC chargers and solar charge controllers ?

John
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#7
(07-06-2017, 10:52 PM)Inverted 18650 Wrote: Here's a quick shot of the first of six new 8 x 30 ( approx 500Ah ea) packs. It's The 1st time I've tried to use the twisted wire busbar setup. I used 3 x 14AWG wires twisted together, then made two separate runs and tied it all together at the top with a #4 lug.

Beautiful!!
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#8


Pack #2 of 6. This one is only 8 x 27 because I used 2600mah cells. Its a bit over my target of 500Ahs but that's better than being under. I tried it with just 25 cells and it looked too odd. I had to extend the copper lug wire on the ends a little bit to make sure it still lines up with the other packs, but I'm stoked how it turned out. Loving this twisted wire busbar thing.

I have a bunch of 2200mah cells that are going into the next pack so it will be 8 X 32. Once its done I'll wire them up and put a charge in it for some testing. Stoked to have a place to share this stuff because as anyone who builds these things knows, it takes a lot of your time and sanity and its feels awesome to have a community to share it with. So thank you to everyone for all the comments and likes!

@john mcCoy
Each manufacture is a bit different with their recommended low cut-off voltage per cell. Some makers say its safe to go as low as 2.5V, while other use the 3.5V figure. For my testing I use 3.0V cut-off. I've tested a few down to 2.5V but the curve drops off so dramatically below 3.0V that the power your getting out of the cell is not worthless compared to the stress its putting on the cell...if that makes sense. You might get an extra 50-75mah's of energy but the damage it can do to the cell is not worth it. When you push a li-ion to its max ( in either direction) it stresses the cell and can greatly reduce the life cycle. Since many of these cells are repurposed already, I don't want to degrade the cell any further an never go below 3.0V. If one of the cells I get from a laptop pack is already below 3.0V, then I charge it at just .050mah until it reaches the 3.7V mark and then slowly increase the current. If it holds the charge then I will cycle it three or four times to make sure it doesn't overheat or act up before I put it in the 'good' pile.

Safety for High Voltage (HV) disconnect: I have disconnect switches (made by SMA who make SunnyBoy Inverters) installed between my panels and the inverter (on each string), between the battery and the inverter, & between the inverter and the fuse panel box. I only have the SMA branded switches because I got an amazing deal on them but I'm sure any HV disconnect will work. I think a switch that can handle the high CURRENT is more important for most of our applications, but it depends greatly on how your array is setup.  I'll post a pic of the switches shortly so you can see the one I am using.

Thanks again everyone and I'm stoked and honored to be a member of your community.

SMA disconnect

AvgRageJoe..dude I built the bars based on your video. I love your humility man, who else would splice in the bloopers and out takes. I dig it. I'm going to check out some of your others now. I'm at the bench soldering for a few hours so I'll run your playlist. Thank again for the busbar idea.
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#9

Another happy "camper". Literally! Installed this one in an RV under the fold away couch. The bank tested out just over 550Ah's and bounced back up to 10.5V after being discharge down to 9.0V for the load test. Pretty stoked...

I'm planning a new design for my next build. It's a blend of the old and the new and some things that have never seen/ done before  with 18650 builds. I'll keep ya posted.

Cheers
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#10
10.5 down to 9V sounds alot! Either you pushed the cells way to much or you have huge voltage drop in the wires. But with that amount of cells it sounds like either HUGE load or actually to small wires Smile

Neither less it's an impressive build.
Follow me! >> YouTube / Forum system setup / My webpage  Diy Tech & Repairs

Current: 10kW Mpp Hybrid | 4kW PIP4048 | 2x PCM60x | 83kWh LiFePo4 | 10kWh 14s 18650 |  66*260W Poly
Upcoming: 14S 18650~30kWh | Automatic trip breakers, and alot more
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