Beginners Guide to Processing 18650 Cells | Cell Database


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Portuguese Powerwall in Poland
#21
Emoncms does it out of box. Works with graphite too
Its just a matter of calculating the area.

New scripts will be supplied with the iso soon.
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Current: 10kW Mpp Hybrid | 4kW PIP4048 | 2x PCM60x | 83kWh LiFePo4 | 10kWh 14s 18650 |  66*260W Poly
Upcomming: 14S 18650~30kWh | Automatic trip breakers, and alot more
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#22
Here's what I've been up to since last update:

I decided to buy unused old stock samsung 29E to reach the 80p which means I'll have ~10kwh powerwall.
These cells costed me ~0.80 EUR/cell, so that gives ~75 EUR /1kwh, that's quite good considering it's cells with original capacity. 

My laptop processing results are 40% good cells, which at around 1EUR per laptop pack gives ~37EUR/1kwh. 

So basically I come to the conclusion that paying 2x more per 1kwh is worth since the laptop batteries are of unknown state-of-life, and these are theoretically new, and don't have to spend time opening the laptop packs.

I have at the moment ~5kwh from laptop cells, and 5kwh from unused old stock, which means that total cost of cells for my 10kwh is ~600 EUR.
That's quite good I think. Let's see how long they last, hoping for at least 5 years if I treat them nicely.

So moving forward with this I soldered all the cells:



prepared the bus bars:



had to buy a torch to solder the lugs:



I'm quite happy with the end result:



Then I started building some kind of holders to keep the packs in the wall.
I kind of followed Pete's design, but did it with just wood and aluminium, so it's kind of DIY of the DIY Smile

 

It's an incredible feeling to see all the 14 packs up in the wall.

 

When I started this endeavour a year ago and open up my first laptop pack I didn't dream that I would come this far, I was thinking maybe a 1kwh powerpack of some kind for charging small electronics, but a house powerwall seemed to me like something out of my reach. Thanks to all youtube videos of Pete's/Daniel's/Joe's and others, and with the help of the forum, I slowly become confident it will be possible even for me to do it Smile
This DIY community is awesome!

I bought a ABB shunt trip, the same as Wim and Daniel so I'm hoping it will work nicely with Batrium's Watchmon (or at least Daniel will come up with a way to make it work nice, I'm counting on him Smile ).



So the current state is that I'm soldering the glass fuses:



I'm using the 1.5amp version, hoping that voltage drop at small loads per cell will not be relevant.

Still have to connect the longmons.

In next few weeks I'll have them ready to connect them up to the PIP.

I'm thinking to test each packs capacity to try and make sure they're within very close capacity to each other, but testing something like 200ah packs with an icharger 5amp discharge will take almost 2 days per pack, and I don't know if even my icharger 106b will be able to measure/show above 99,999mah.
Otherwise I'll just connect them to Batrium and see if they are somewhat close enough that will not cause to much bypass at top.

Feeling quite excited because I start to see the light at the end of tunnel, after so many hours of working on this.
Also thinking about purchase another 3 solar panels to have at least 1.5kWp. Maybe even more if winter sun hours are not enough to charge 10kwh powerwall given 2 days of sunny winter weather.

I'm also impatiently waiting for Daniel's new soft for the Batrium/MPP, since I want to controll PIP AC charging from raspberry ( will probably need to use custom firmware from http://forums.aeva.asn.au/).

Basically I want to charge a bit the powerwall (if SOC it low) during nightly cheap tariff IF weather forecast for next day doesn't predict too much sun hours.
This way I hope to never again have to pay peak tariff from grid even when a few winter days without sun.

Also I tested emoncms for calculating KWH from power samples, and given they're 10seconds it's a bit off compared to SDM120 kwh.
So I'm thinking still on how to precisely calculate kwh for a few things: 1) PCM solar charging 2) battery IN/OUT.

Daniel says that with influx queries some kind of value is possible, but not the best way. I'll look into that.
And also the new shunt from batrium maybe it will be able to calculate kwh besides the ah for daily charge/discharge.
That used in conjunction with the SDM120 meters, would allow to have daily kWh values available for all of these:

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#23
Very nice setup. I will have to say, OCD was calmed by those pictures Wink Very cleanly done

I do wonder, though. Did you solder the lugs on the copper busbars? There's a lot of space visible in the one pic of the closeup of the lugs; and looks like you vise pressed them instead of crimping. This could lead to problems down the road as the metals shrink/contract over time. But then I see you have shrink wrap on them already. So, I'm hoping they are really solid now Smile
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#24
(10-23-2017, 11:53 AM)Korishan Wrote: I do wonder, though. Did you solder the lugs on the copper busbars? There's a lot of space visible in the one pic of the closeup of the lugs; and looks like you vise pressed them instead of crimping. This could lead to problems down the road as the metals shrink/contract over time. But then I see you have shrink wrap on them already. So, I'm hoping they are really solid now Smile

Yes, I vise pressed them, don't have a crimp yet. And then I soldered them with the torch in the picture. The closeup pic was before the soldering.
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#25
I have done several tests with the shunt and it tops out at 5-8A when tripping. Or atleast minimum that Smile

So Im waiting answer from Batriums engineer in terms of what their most-fet output can or will handle. So when I get that I will be posting the "Ultimate way to wire your shunt to batrium" up in close collaboration with Jaron directly. Currently I have only tested it with the relay.

And next gen of Watchmon will have even better features for it.
Frnandu Martiński likes this post
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
Upcomming: 14S 18650~30kWh | Automatic trip breakers, and alot more
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#26
The ABB shunt trip you (we) have there works already with the watchmon... no problem using it right now until Daniel is ready with the ultimate way to hook it up...
I have, for now, made a middle connection on my 48v setup to get the 24v needed for the shunt.
A relay of the expansion board is selected to be disabled in case of a critical event ( so the relay is activated in normal use ) because the relay's on the expansion board have only a no contact i have a secondairy (12v)relay with a nc contact to activate the shunt.
The secondairy relay is also activated in normal use and drops of in case of a critical event the nc contact closes and activates the shunt.

The ABB shunt only draws current the few ms when tripping, there is no current after or before tripping ( only during the event )
Only drawback is there are 2 relay's activated all the time in normal use...
The new Batrium software has a "Pulse" setting that makes it possible to eliminate the extra relay, but i kind of like the way it is now... the advantage is in case the batrium stops working (ie a power failure ) the relay drops of and activate the shunt... a extra failsafe.
atleast in my head  Wink

So, until Daniel finds the perfect way to use the shunt trip i leave it this way.... far more safer then no shunt trip in the system at all. Big Grin
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18x 300Wp solar off grid and 10x 180Wp solar tracker grid-tie
10KW 3phase hybrid inverter. 25Kwh 18650 storage (for now)
My setup: http://www.diypowerwalls.com/t-Instant-powerwall
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#27
Can you link which exactly relay you're using?
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#28
each relay with a nc contact will do just fine...
i used one a had laying around here.

something like this is perfect http://www.benl.ebay.be/itm/MY4NJ-DC-24V...Sw8lpZFHcT
Frnandu Martiński likes this post
___________________________________
18x 300Wp solar off grid and 10x 180Wp solar tracker grid-tie
10KW 3phase hybrid inverter. 25Kwh 18650 storage (for now)
My setup: http://www.diypowerwalls.com/t-Instant-powerwall
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#29
You dont need any relay extra and you dont need to run it in middle either if you dont want to Smile
You can use the built in relay on the expansion board and there is no problems what so ever running it on 48V directly. I have tested this and it runs fine for the short period as such. Though an extra resistor doesnt hurt to divide the voltage down a slight bit. That makes the connection easy.
It takes 10-14mS for it to trip and no problem there either Smile


The way i plan for is where you dont even add any extra wires from the battery but power it from the incomming power on the board kind of Smile But lets see about that.
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
Upcomming: 14S 18650~30kWh | Automatic trip breakers, and alot more
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#30
Thanks guys for help with the shunt trip. I'll try it out once I have the packs ready.

Meanwhile I tested first 80p pack for capacity, and icharger 106b was able to discharge at around 4amp giving a result of 198ah, it took almost 48h.
I'm aware that:
1) such low amperage will probably result in higher capacity that normal day usage, i.e. loads of 1500w for 1h (water boiler)
2) This was from 4.2v to 3.0v, but to extend life, I will rather not go outside 4.1-3.3v, but it's good to know how much there is if needed for emergencies.

Given that, I tested it mainly to check pack's capacity consistency.
Testing all other 13 packs still will take almost a month. Is it worth to confirm packs equal capacity? I used all my cells above 2000mah to fill 14s80p, so there was not equal amount of cells for each 100mah intervals. That's why I'm not confident that packs capacity will be equal enought.

Anyway, let's see after a few more packs if capacity keeps close enough.

Also one problem I found is that after soldering 1 or 2 cells per packs are at 0v or close to 0v. Does this mean I applied too much heat and destroyed them? 
This is a bit annoying since now I have to fill the holes left from those bad cells with >1900mah cells and will probablby result in not so much balanced capacity among packs.
Do you guys also have this happen to you?
I really try to be quick with the solder iron, but still am getting bad cells after soldering Sad
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