Frank, why wouldn't you hold the sections together and solder them together instead of crimping? It would be fairly quick with a torch and solder. I think you should be good but it would ensure you have a solid electrical connection between segments that isn't susceptible to oxidation.
Got a question on your BMS if you got a minute? Are you attaching your leads to the first battery of the parallel battery? Or are you going to +/- of each battery? The later is what I was thinking was how a normal way to connect an BMS.
what would 2 10 gauge wire be equal to. about 7 ga? I'm planning to connect them to a small 1/0-2/0 buss. with 0ga. to the inverter. 5' long. with the cable connected in center. so it is like doubled. the cells will be connected to opposite ends. then to the buss.
Check this out for combining wires - www.wirebarn.com/combined-wire-gauge-calculator_ep_42.html And then check here to see how much amperage (in chassis wiring) that gauge can handle - www.powerstream.com/Wire_Size.htm
Thanks Joe. Quick question for you, I noticed that you have commenting turned off on your channel (at least the ones where I want to leave a comment). Is there a reason you have it turned off. Frank@thediyengineer.com
I used 10 gauge solid wire. and made a loop of sorts. so its doubled 10 gauge. and I have average Joe glass fuses. I haven't actually assembled anything yet. but I don't like them. its 40 cell packs . all paralleled. then the packs get wired 7s. I'm planning on 100-120a max peak current. for now until I get more cells. my cells will do 5a continuous. but I hope to get the peak current down to 100ma eventually. that will take lots of cells. I haven't done the maths. 225-250 amps divided by .100 amps. eq. lots of 18650's my 5kw inverter plus a few amps for DC loads. about 10a or so. my bank needs to be more of a cube. than a flat.. I'm wondering about the purity of the copper . I never had copper change so many colors when heated to solder. blue purple maroon . its cheap wire from amazon. great video. between my lead acid T-105 . and adding the lithium cells. hopefully I can at least go 8-10 hours without running the generator. and I'm getting solar panels. soon. but that will only charge at under 30a. so I need to build a tracker. I'm thinking about a a small tracking system of 600 to 700 watts. and put the rest on the roof. or ground mounted. then I can at least get the most from some of the panels. I'd like to have the whole array track. but I don't see that happening. what charge controller are you going to use? I'd like to get a flex max. but I'm using a epever tracer. and thinking about getting a Esmart3, when I get more panels. sorry I'm rambling again. I hope to get about 500ah more battery. and to about 2500w in solar. this summer. I'll have nearly 1000ah then. I know it would take forever to charge 1000 ah with 2500 in solar . while using power also. I'm working on a gas powered 150 amp generator. to make up for sunless days and heavy use. I mostly just run a fridge and a freezer and a TV. with an occasionally microwave and 7amp well pump. keep at it.
Wow James you have a lot going on. Are you using new or harvested 18650 cells? If they are harvested, I don't think I would push them past 2C (2x the capacity of the cell). So if your 40 cell are testing out at 2100mAh then the most I would push the pack is about 160 amps. So I have not decided on a long term charge controller. I do like the Outback controllers, but I still need to do more research. My powerwall will start out with a 3000va APC UPS I picked up for $100. It runs at 48 volts. After doing a ton of reading, thought it would be best to start with a 48 volt system. Well good luck with your system, please let me know how it goes. Thank you for commenting!!! Frank
Frank Brand my cells are new 2600 LG cells. I have some high drain Samsung 1500 cells I also was thinking about adding. to help with the current. they are new also. but I found a bad cell in them. it had a high resistance. the tester started with about 950mr. my other cells are like under 060mr. and the bad 1500 cell. come in under 500 mah. and the voltage drop from 4.2 to 3.4v was most instantly at only .5 a discharge. I even retested it 2 more times. the resistance got better. but the ah. dropped. so I gave up . I thought my test was off. so far the 2600's are doing 2680 and up! and one that was really close to 2600. I'm gonna try to not use it. only the highest capacity cells. I can charge 16 cells at once. and and discharge 5 at once. I'm still waiting for that slow boat!! keep it up. and thanks..
Frank Brand zanflare C 4, I'm going to retest some with the discharge boards if they ever get here! I don't completely trust these numbers. it maxes out while testing at 500ma charge and discharge. and will just charge at 1a. I'm using the tp4056 to precharge. I been charging batteries so long. it seems like a new way of life. I even get up in middle of the night. to change batteries. for like a month now. and its about time to buy more cells. I guess I need more dischargers also . if the ones I ordered don't arrive soon!
great work, just getting started, would like a copy of your spread sheet to keep a complete record, but the only address i found so far did not work. Could not find a download link on thediyengineer.com . Again thank you for your explanations of different configurations for the purpose of the pack and the vidion on the charging board.
Here is a link to get a copy of the cell tracking spreadsheat: thediyengineer.com/18650-cell-harvest-tracker/ When the link takes you to the Google Docs page you will need to click on "File" and click on "Make a copy" It will then be saved to your personal documents. Let me know if you have any issues.
Looks like it will work fine, please do a follow up video showing installing them.
Nice mod on the busbars! I buy "excess" power wires, which often are too short... this is the solution. thanks!
Your welcome, thanks for watching!!!
Frank, why wouldn't you hold the sections together and solder them together instead of crimping? It would be fairly quick with a torch and solder. I think you should be good but it would ensure you have a solid electrical connection between segments that isn't susceptible to oxidation.
I still have 2 more packs to build so I just might try that in the future. Thanks :-)
Hi Frank from Aussie great video from start to end no B.S all good info.........Enjoyed and subscribed
Got a question on your BMS if you got a minute? Are you attaching your leads to the first battery of the parallel battery? Or are you going to +/- of each battery? The later is what I was thinking was how a normal way to connect an BMS.
what would 2 10 gauge wire be equal to. about 7 ga? I'm planning to connect them to a small 1/0-2/0 buss. with 0ga. to the inverter. 5' long. with the cable connected in center. so it is like doubled. the cells will be connected to opposite ends. then to the buss.
Check this out for combining wires - www.wirebarn.com/combined-wire-gauge-calculator_ep_42.html
And then check here to see how much amperage (in chassis wiring) that gauge can handle - www.powerstream.com/Wire_Size.htm
That's awesome. THank you for sharing!!! Frank
Amazing as usual ! Wow Frank, your videos are so awesome. How do you it?
Thank you Ray, you are so supportive!!!
I soldered my 10 ga with a 150watt iron. . maybe you could solder yours also?
If you are using copper, a single strand of #10 is rated at 30-35 amps, so when doubled you should be ok up to 60-70 amps.
Interesting Idea!👍
Thanks Joe. Quick question for you, I noticed that you have commenting turned off on your channel (at least the ones where I want to leave a comment). Is there a reason you have it turned off. Frank@thediyengineer.com
Comments should be enabled but Ill check on it. Thanks for letting me know!
What the heck happened to your thumb?!? Oh, excellent video too!
I used 10 gauge solid wire. and made a loop of sorts. so its doubled 10 gauge. and I have average Joe glass fuses. I haven't actually assembled anything yet. but I don't like them. its 40 cell packs . all paralleled. then the packs get wired 7s. I'm planning on 100-120a max peak current. for now until I get more cells. my cells will do 5a continuous. but I hope to get the peak current down to 100ma eventually. that will take lots of cells. I haven't done the maths. 225-250 amps divided by .100 amps. eq. lots of 18650's my 5kw inverter plus a few amps for DC loads. about 10a or so. my bank needs to be more of a cube. than a flat.. I'm wondering about the purity of the copper . I never had copper change so many colors when heated to solder. blue purple maroon . its cheap wire from amazon. great video. between my lead acid T-105 . and adding the lithium cells. hopefully I can at least go 8-10 hours without running the generator. and I'm getting solar panels. soon. but that will only charge at under 30a. so I need to build a tracker. I'm thinking about a a small tracking system of 600 to 700 watts. and put the rest on the roof. or ground mounted. then I can at least get the most from some of the panels. I'd like to have the whole array track. but I don't see that happening. what charge controller are you going to use? I'd like to get a flex max. but I'm using a epever tracer. and thinking about getting a Esmart3, when I get more panels. sorry I'm rambling again. I hope to get about 500ah more battery. and to about 2500w in solar. this summer. I'll have nearly 1000ah then. I know it would take forever to charge 1000 ah with 2500 in solar . while using power also. I'm working on a gas powered 150 amp generator. to make up for sunless days and heavy use. I mostly just run a fridge and a freezer and a TV. with an occasionally microwave and 7amp well pump. keep at it.
Wow James you have a lot going on. Are you using new or harvested 18650 cells? If they are harvested, I don't think I would push them past 2C (2x the capacity of the cell). So if your 40 cell are testing out at 2100mAh then the most I would push the pack is about 160 amps.
So I have not decided on a long term charge controller. I do like the Outback controllers, but I still need to do more research. My powerwall will start out with a 3000va APC UPS I picked up for $100. It runs at 48 volts. After doing a ton of reading, thought it would be best to start with a 48 volt system. Well good luck with your system, please let me know how it goes. Thank you for commenting!!! Frank
Frank Brand
my cells are new 2600 LG cells. I have some high drain Samsung 1500 cells I also was thinking about adding. to help with the current. they are new also. but I found a bad cell in them. it had a high resistance. the tester started with about 950mr. my other cells are like under 060mr. and the bad 1500 cell. come in under 500 mah. and the voltage drop from 4.2 to 3.4v was most instantly at only .5 a discharge. I even retested it 2 more times. the resistance got better. but the ah. dropped. so I gave up . I thought my test was off. so far the 2600's are doing 2680 and up! and one that was really close to 2600. I'm gonna try to not use it. only the highest capacity cells. I can charge 16 cells at once. and and discharge 5 at once. I'm still waiting for that slow boat!! keep it up. and thanks..
James, what cell tester are you using?
Frank Brand zanflare C 4, I'm going to retest some with the discharge boards if they ever get here! I don't completely trust these numbers. it maxes out while testing at 500ma charge and discharge. and will just charge at 1a. I'm using the tp4056 to precharge. I been charging batteries so long. it seems like a new way of life. I even get up in middle of the night. to change batteries. for like a month now. and its about time to buy more cells. I guess I need more dischargers also . if the ones I ordered don't arrive soon!
great work, just getting started, would like a copy of your spread sheet to keep a complete record, but the only address i found so far did not work. Could not find a download link on thediyengineer.com . Again thank you for your explanations of different configurations for the purpose of the pack and the vidion on the charging board.
Here is a link to get a copy of the cell tracking spreadsheat: thediyengineer.com/18650-cell-harvest-tracker/
When the link takes you to the Google Docs page you will need to click on "File" and click on "Make a copy" It will then be saved to your personal documents. Let me know if you have any issues.
hi why use busbars?
FOUND IT did not capitalize HEXTWP
Oh good. I just replied to you last comments. :-) Let me know if you have any questions.
Enjoy woodprix woodworking instructions.