Beginners Guide to Processing 18650 Cells | Cell Database


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Mike's DIY Powerwall
#1
I have been working on this project for a few months now, so rather than try to rehash everything thus far, I will just start the thread by discussing where I am at now, then post updates along the way.

I am building packs of 120 cells in parallel. I would estimate the average capacity per cell to be 2200mah. That gives me ~264ah per pack. This is the very first pack i made. I went with similar design as Peter, with a few changes. I am doing 6 wide (3 bus bars) rather than 4 (2 bus bars). Additionally, I decided to fuse both ends only because the fuse wire is so cheap, why not. Aside from that, it's mostly the same.
[Image: dUxLKJiQ.jpg]

Each bank consists of 7 packs, or 25.9v nominal voltage. This is the first bank I built. At the time of this post, it has been in service for 6 weeks and is still working great. The voltages per pack (when charged) only differ by 0.02v at most. When discharged, there are 2 week packs that fall to around 2.8v while the others remain at 3.3v. I will need to rebuild these packs at a later date.
[Image: jBowwAov.jpg] [Image: FuWlLVYA.jpg]

This is the second bank (packs 8-14) that I just finished a couple of days ago. I'm trying to come up with a way to capacity test the packs so I can group similar capacity packs together.
[Image: hJxfucCa.jpg]
Solar Setup: 9x 320w panels, PCM60X charge controller
Battery Setup: 14x 120 cell 18650 packs, 48v configuration

Recommended Items:
Opus BT-C3100, Cell Heat Shrink, 4-Cell Holders
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#2
Nothing too special here. A standard Tracer charge controller and cheap inverter. I'm working on upgrading the equipment slowly. I did receive a PCM60X earlier this week which has been running for a few days now. I will post pictures/updates once I have more to share.
[Image: Bji3sKl8.jpg]
Solar Setup: 9x 320w panels, PCM60X charge controller
Battery Setup: 14x 120 cell 18650 packs, 48v configuration

Recommended Items:
Opus BT-C3100, Cell Heat Shrink, 4-Cell Holders
Reply
#3
What is the small box, on the bottom?
Cell progress: 2016/10/17:
180cells@2.0
600cells@2.1-2.6a
70cells@2.7a+

Projects:
Mobile PowerBox
8Kw Powerwall
Insight Parallel PowerPak
1Kw PowerBlade
PowerRack (concept)
12v LED Sconce
Reply
#4
Toochi84 Wrote:What is the small box, on the bottom?
It's just a digital display for the charge controller. It shows the voltage, amps, etc. It has since been replaced with the PCM60X. I'll post a new picture once it is all pretty and organized.

<!-- m --><a class="postlink" href="https://www.amazon.com/Sun-YOBA-Tracer1210RN-Tracer1215RN-Tracer2210RN/dp/B00ECVWDGC/">https://www.amazon.com/Sun-YOBA-Tracer1 ... 00ECVWDGC/</a><!-- m -->
Solar Setup: 9x 320w panels, PCM60X charge controller
Battery Setup: 14x 120 cell 18650 packs, 48v configuration

Recommended Items:
Opus BT-C3100, Cell Heat Shrink, 4-Cell Holders
Reply
#5
mike Wrote:Nothing too special here. A standard Tracer charge controller and cheap inverter. I'm working on upgrading the equipment slowly. I did receive a PCM60X earlier this week which has been running for a few days now. I will post pictures/updates once I have more to share.
[Image: 3WllrcH.jpg]

Are you charging the batteries direct from the tracer? Are you disabling the float charge?
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#6
Chickey Wrote:
mike Wrote:Nothing too special here. A standard Tracer charge controller and cheap inverter. I'm working on upgrading the equipment slowly. I did receive a PCM60X earlier this week which has been running for a few days now. I will post pictures/updates once I have more to share.
[Image: Bji3sKl8.jpg]

Are you charging the batteries direct from the tracer? Are you disabling the float charge?

Yes. They are connected directly. I just picked a battery setting that had a maximum voltage (bulk, float, equalization) below 28.7 (4.1*7). It is not the correct way to do it but it worked for the couple of weeks until my PCM60X arrived Smile
Solar Setup: 9x 320w panels, PCM60X charge controller
Battery Setup: 14x 120 cell 18650 packs, 48v configuration

Recommended Items:
Opus BT-C3100, Cell Heat Shrink, 4-Cell Holders
Reply
#7
[Image: UQue8ktR.jpg]

New 320w panels ready to install as soon as I can figure out how to attach them to the roof! Also converting the battery system to 48v for this. I need to go back and resolder 7 of my 14 packs so the busbars alternate each end.
Solar Setup: 9x 320w panels, PCM60X charge controller
Battery Setup: 14x 120 cell 18650 packs, 48v configuration

Recommended Items:
Opus BT-C3100, Cell Heat Shrink, 4-Cell Holders
Reply
#8
They are alot bigger than i thought they would be. Even tho i saw the dimensions when purchased. Reading and handling are two very different things.
Cell progress: 2016/10/17:
180cells@2.0
600cells@2.1-2.6a
70cells@2.7a+

Projects:
Mobile PowerBox
8Kw Powerwall
Insight Parallel PowerPak
1Kw PowerBlade
PowerRack (concept)
12v LED Sconce
Reply
#9
mike Wrote:[Image: ORNsS2U.jpg]

New 320w panels ready to install as soon as I can figure out how to attach them to the roof! Also converting the battery system to 48v for this. I need to go back and resolder 7 of my 14 packs so the busbars alternate each end.

wow, that's a lot of solar power you got there Big Grin NICE!

Please do share how you end up mounting 'em

(Thanks for your awesome youtube channel!)
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#10
super heavy too when you try to move them solo. I have 3 and it was awkward trying to maneuver them on to the rack. I'm not sure about roof mounting, but i used super strut attached to a wood frame to mount mine. Might be able to devise some roof mounts for the super strut.
Off Grid Setup
3 - 320watt 24v Panels - MPPSolar 2424LV-MSX - 672 Cell 96p7s 5.5kw Power Wall

Retired pack 2kw 420 Cell

On Grid Setup
44 - 250 Watt Panels with Enphase micro inverters
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