Gr00ldude48
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Yes I definitely don't want to weld anything! I designed the busbars to have dedicated threaded holes for the balance lead just incase so thats a win.
48v 64 cell SAB 60280 Batrium K9 Rack Build
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Gr00ldude48
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At least itll look like a pretty ornament if I welded everything together. But Thanks to everyone's input I may not have just an ornament heh heh
Gr00ldude48
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K tore the current battery build back down, removed all the fiber washers, bolted everything back nice and tidy, was so lovely not having to fidget with all those leads while building the battery. Installed battery in rack.
Next step is wiring BMS leads to holes I originally had tapped in each busbar specifically for BMS leads.
Next step is wiring BMS leads to holes I originally had tapped in each busbar specifically for BMS leads.
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Very attractive use of components, and a lot of effort on your part. Overall, I distrust any system whereby a dropped wrench, or a piece of metal such as a wedding ring could cause a massive arc. When I work on cells on my bench-top, I always cover terminals with a piece of heavy cardboard and some temporary tape just in case. By the way, kudos for a clean work-space!
I'd incorporate some clear Lexan shields into your project when you have the final configuration worked out.
I'd incorporate some clear Lexan shields into your project when you have the final configuration worked out.
Gr00ldude48
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Thank You! I concur, I was definitely planning on fabricating shields, I did this with my previous system too once a figured out the wiring schematics. I've got some cool ideas ?
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alvirtuoso
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Does your batrium communicates with your Growatt?
Gr00ldude48
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Havent got that far yet, not sure how many resources/support is online for the Batrium to communicate with the Growatt. We will see ?
Maintenance guy
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I am so glad you removed those fiber washers as these cells were not designed to be mounted that way. @ 110 amp per cell capable i am glad you changed your mind.
Beautiful set up capable of 440 amps @ 48 volts, very nice.
Beautiful set up capable of 440 amps @ 48 volts, very nice.
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Gr00ldude48
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Thank You! Finished Second battery, built without fiber washer last night, tore down first battery today and took out fiber washers and rewired leads. Put second battery online today after wiring the DIN rail hardware. Keeping the First battery offline until I get the second battery down to the same voltage as the first then I'll bring them up together. I have two more battery racks to build after these two ? Should be a beauty! I'll clean up wire routes once I get everything in the final position.
sunshine_eggo
Happy Breffast!
You have constructed a most luscious nightmare. I truly mean that in a positive way. I'm glad I made it through to the end of the thread and see that you've removed the washers.
If someone mentioned it already, I apologize, but you can still get individual cell monitoring simply by treating each column of cells as individual batteries only paralleled at the end terminals:
On the opposite side, you could cut it from top to bottom.
Basically cut there between each column to isolate each. I realize that's going to make suspending them a challenge, but if you want to retain individual cell monitoring, it's an option.
Gr00ldude48
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Much appreciated advice, no one has mentioned that thus far; so Thank You! I do understand your suggestion; suspending that properly would be intense... an engineering feat haha. But I guess that wouldn't be but a bit more brainwork on the CAD software for the CNC. Sounds like a fun challenge to tackle. Once I get this all up and running I'll see what I can come up with. How would you suggest running the Batrium leads for individual monitoring?
sunshine_eggo
Happy Breffast!
Hmm...
It appears to me that the terminals of the bottom cells are supporting the entire column above and then the bottom barrel of the cell supporting everything? If that's the case, I would be concerned about the terminals' longevity. Since you've already established the bottom barrel as being sufficiently strong to support the whole column, I would explore spacers between cells and then using the phenolic blocks to join the columns where cut for improved stability.
NVM: I assume the posts and orange discs are the supports now that I look at the other one.
It appears to me that the terminals of the bottom cells are supporting the entire column above and then the bottom barrel of the cell supporting everything? If that's the case, I would be concerned about the terminals' longevity. Since you've already established the bottom barrel as being sufficiently strong to support the whole column, I would explore spacers between cells and then using the phenolic blocks to join the columns where cut for improved stability.
NVM: I assume the posts and orange discs are the supports now that I look at the other one.
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sunshine_eggo
Happy Breffast!
CAD? CNC? Pfft. Die grinder or chop saw, several wheels, and an afternoon.
I have often spent many hours more time exploring options in Solidworks than it would have taken me to fix it in the real world. Watch out for that...
Gr00ldude48
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I 3D printed blue bushings that fit between every row of cells and orange bushings that 5/8 threaded steel rods run through the server rack and busbar to support the weight. The bottom cells are suspended mid air and touch nothing ? The foam pad was temporary to get initial height for when I put my first support rod In. Yes I also like the phenolic block idea to join columns!
I scrapped this wiring idea just showing the bushings for cell support. I made sure everything is within thousands of an inch in Accuracy to get maximum support. I gave the busbar terminal holes a bit of extra leeway for mounting ease. But when I bolt up the busbar support blocks it pulls everything square due to the bushing placement and size.
Gr00ldude48
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Chuckles** I feel you on that one! I only need a food break when working in the garage, I need a triathlon to expend the frustration built up from what that software does to me at times ?CAD? CNC? Pfft. Die grinder or chop saw, several wheels, and an afternoon.
I have often spent many hours more time exploring options in Solidworks than it would have taken me to fix it in the real world. Watch out for that...
Maintenance guy
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Wow what a system and great pics. i am so drooling profusely.
Cells are running around 58 ah testing so your monster system is at 928 ah @ 48 volts capable of pushing 1760 amp @ 48 volts @ over 7000 bucks for the cells alone. i think i just peed on myself.
One of the most professional jobs i have seen, hats of to ya !
Cells are running around 58 ah testing so your monster system is at 928 ah @ 48 volts capable of pushing 1760 amp @ 48 volts @ over 7000 bucks for the cells alone. i think i just peed on myself.
One of the most professional jobs i have seen, hats of to ya !
sunshine_eggo
Happy Breffast!
Yeah, sorry. I was just working with the image I cropped, and it wasn't punching me in the face, so I missed it.
BuffaloTrace
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Does everyone agree the busbar should come into direct contact with the top of the cell terminal on basically any system?
This setup is amazing, that's the only fault point that I see, looks like an easy fix to an excellent battery bank.
This setup is amazing, that's the only fault point that I see, looks like an easy fix to an excellent battery bank.
sunshine_eggo
Happy Breffast!
Gr00ldude48
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Thank You! Due to the awesome members of this forum and their advice; I removed all fiber washers and terminal rings and directly mounted busbars to battery terminals. I ran BMS leads into tapped hole in Busbars. So before I ran into major issues the risk should be eliminated befor any load is put on batteries ?
Gr00ldude48
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If anyone is interested in some extra K9's I have up for sale.
Thread 'New Batrium K9's w/ Accessories [USA]' https://diysolarforum.com/threads/new-batrium-k9s-w-accessories-usa.32262/
Thread 'New Batrium K9's w/ Accessories [USA]' https://diysolarforum.com/threads/new-batrium-k9s-w-accessories-usa.32262/
Gr00ldude48
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This should do ?
Maintenance guy
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If anyone is interested in buying copper bus bar cheaper then anywhere else and making their own in the US.
i buy from them all the time and am pleased with the service. when bought in 12' lengths each bus bar is under 3 dollars depending on length. i saved 4 to 5 dollars a foot compared to ebay. their Aluminum is way cheaper also.
Also if you want extravagant and go with silver plated bus bar.
www.mcmaster.com
unfortunately this is only 1/4 inch thickness but their service is very good and stand by their products.
i buy from them all the time and am pleased with the service. when bought in 12' lengths each bus bar is under 3 dollars depending on length. i saved 4 to 5 dollars a foot compared to ebay. their Aluminum is way cheaper also.
Also if you want extravagant and go with silver plated bus bar.
McMaster-Carr
McMaster-Carr is the complete source for your plant with over 595,000 products. 98% of products ordered ship from stock and deliver same or next day.
unfortunately this is only 1/4 inch thickness but their service is very good and stand by their products.
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sunshine_eggo
Happy Breffast!
1/8" x 3/4" wide 6 foot is about 10% cheaper at McMaster.
Gr00ldude48
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If anyone is interested in buying copper bus bar cheaper then anywhere else and making their own in the US.
i buy from them all the time and am pleased with the service. when bought in 12' lengths each bus bar is under 3 dollars depending on length. i saved 4 to 5 dollars a foot compared to ebay. their Aluminum is way cheaper also.
Also if you want extravagant and go with silver plated bus bar.
McMaster-Carr
McMaster-Carr is the complete source for your plant with over 595,000 products. 98% of products ordered ship from stock and deliver same or next day.
unfortunately this is only 1/4 inch thickness but their service is very good and stand by their products.
I bought my copper busbar from McMaster as their shipping has been quite consistent. I'll have to check out the other site he mentioned. Hopefully I don't have to buy anymore anytime soon haha.
