64 eve lLF280k version3 cells in 8P8S configuation 24-volt build December 28th, 2023

[Steve_S]

64 cells 280Ah version 3 cells:

My March 25 2024 progress:
Black 4/0 copper cables are 16 inches and now have the heat shrink...(Carolpreme is the brand of the 4/0 cable made in the USA);
I found some red heat shrink for red 12-inch 4/0 copper cables (Temco brand)(tomorrow maybe if I have time to heat shrink the red ones)
snowing again
View attachment 204749View attachment 204750View attachment 204751View attachment 204752View attachment 204753

Gee, Deja-Vu / Flashback...
Doing my own systems, I spent 2 Long & Tedious days cutting, crimping and Heatshrinking alone and NOT short easy days either...
Now I am going to do it all over again as I am redoing my whole bank & adding another 21kWh into it. At least I won't be using 4/0 for the packs to main DC bus again. I use Royal Excelene Fine Wire Welding wire (made in USA) which is also perfect for this use.

 

[michael d]

64 cells 280Ah version 3 cells:

Here is a 4P8S color diagram from Filter Guy's PowerPoint reference on this DIY Solar forum.
I flipped it upside down as my positive is on the left end and my negative is on the right end.

If you double that you will get the 8P8S I am assembling....
In my build there are eight red positive copper 4/0 AWG cables from the positive end,,, and eight black 4/0 AWG copper cables from the negative end (an 8 x 8 64-cell build = 8P8S) they have 0.25-inch lug holes to the battery cells; and 3/8 inch lug holes to the large 0.25 x 4-inch x 24-inch tinned copper busbar...(different tinned copper lug on each end of the hydraulically crimped cables --- of course)



coffee to get warmed up>>> yes
It is raining this morning and cold for the 1st day of April, 2024
Definitely need the rain,,,, but it is miserable for doing the outside off-grid farm chores....

 

[michael d]

64 cells 280Ah version 3 cells:

All connections on the 64-cell battery are done... ((((April 3rd, 2024)))
the small provided Allen key for the grub screws arched the second to the last one so it is really too long or needed a bit of electrical tape or something on the end of it..
I carefully re-snugged all the 30mm long M6 grub screws, but the second to the last one had to touch wrong with the long allen key...
always wakes you up ( that spark )
the battery is at 26.60 volts right now...
I need a few more details and connections yet.... but progress is slow...
large 24-inch x 4-inch x 0.25-inch tinned copper busbar on each end is also fully connected.

 

[michael d]

64 cells 280Ah version 3 cells:

26.60 volts (measured via multimeter) in an 8S battery is at the 90 percent SOC...
so it is time for the NH fuse and inverter connection....
the 3200-watt high-frequency 24-volt inverter will be the easiest to connect for the moment...
more later,,,

 

[42OhmsPA]

64 cells 280Ah version 3 cells:

All connections on the 64-cell battery are done... ((((April 3rd, 2024)))
the small provided Allen key for the grub screws arched the second to the last one so it is really too long or needed a bit of electrical tape or something on the end of it..
I carefully re-snugged all the 30mm long M6 grub screws, but the second to the last one had to touch wrong with the long allen key...
always wakes you up ( that spark )
the battery is at 26.60 volts right now...
I need a few more details and connections yet.... but progress is slow...
large 24-inch x 4-inch x 0.25-inch tinned copper busbar on each end is also fully connected.

Lol. At least you didn't have a cell flipped and connect a busbar creating a dead short, that spark really wakes you up fast .

 

[michael d]

64 cells 280Ah version 3 cells:

April 3rd 2024 progress:
I hooked up the 24-volt inverter and used a 24-volt continuity tester to pre-charge the capacitors in the inverter.... worked great>>> was absolutely no spark when doing the final positive connection to the 3200-watt high-frequency inverter....
this automobile continuity tester has a bulb that will light and go dimm as the capacitors are charged up; but if you have the wires reversed the bulb will continue to be bright and will not go dim.... ( don't ask me how I know >>> duh) things always happen so it is best to test all connections as you go,,,,when tired or in a hurry things always seem to occur...
I turned the inverter off as I had no load for it yet....
I also hooked up the Riden 6024 buck charger and added another 30Ah to the battery and it said 26.85 volt SOC....(((see what it reads in the morning...)))
I set it at 27.00 volts; and later bumped it up to 27.30 volts for charging in the battery charge mode....(((Riden 6024)))
when it reaches the preset voltage it will reduce the current (amps) until it is done....but I still turn it off overnight....
I turned it off overnight.... >>> no reason to let it go unattended for the moment....(the Riden 6024 buck charger)
need to make sure everything is working as designed...
still, a few more connections are to be done with other parts of this 64-cell build....
but the honey-do list will take priority tomorrow...

and another hair sheep lambing so busy busy busy....
lots of sunshine today....




I had to make longer leads for the Riden so I spliced each cable with extra grub screws and serrated flange nuts etc... a lot of tape and plastic around the splice...(not my finest work so no pic of that part >>> I will build better cables in a few days)
I have an 8-ton hydraulic crimper that is good for smaller cables and a 16-ton hydraulic crimper that is better for larger cables....

I also had to make longer inverter cables,,, but I used 5/16 inch stainless steel bolts and washers, etc for that splice and again plastic and lots of electrical tape for that splice (( not pretty but functional for the test )) I will make longer cables in a few days or so....the inverter had 5/16 compatible terminals (but unfortunately), the busbar was set up for 3/8 inches.... (never simple)...different lug needed for each end!!
I used stainless steel bolts and washers etc for all connections!

more another day

 

[michael d]

64 cells 280Ah version 3 cells:
overnight the cells and 64 cell battery settled down to 26.65 volts, so I turned the Riden 6024 on this morning and set the voltage to 27.10 volts for charging a bit more....

Amazon has a "Katzco" continuity tester for $11.99 delivered. it has a bulb that lights and dimms down as the capacitors are charged up in the inverter when doing the initial pre-charge connection....
no sparks using this method...
and this is a tool you can use for other wiring tasks for your 12-24 volt projects...
can not seem to get a picture of it off of Amazon probably have to take a picture of the one out in the solar power shed and post it later...

more later....

 

[michael d]

64 cells 280Ah version 3 cells:
the NEEY 15Amp smart active balancer is running tonight 4/5/2024.
that was easy to hookup, annoying to get the "neey electronics" blue tooth app to work on the android cellular....lots of downloading and re-setting etc, more on that later
A regular pain in the Axx..
but I set the battery as a 2200 Ah 8-cell battery and it started with a 31mV differential.... so not bad to start
for an 8P8S 64-cell battery....using 64 of the new 280Ah eve version 3 cells...

It is at 26.75 volts and I turned the Riden 6024 battery charger on and set it to 26.80 volts for some overnight charging and balancing....
I will go out later and see what it is doing, but the led indicator lights on the NEEY 15Amp active cell balancer and the app show it to finally be functioning...
at least no red warning light now...
green, blue and yellow(the yellow is for balancing/equilization is in progress)

never found an instruction manual anywhere so, I had to go by the off-grid garage YouTube video and wing it some....

 

[michael d]

the NEEY 15Amp smart active balancer :

active balancing the 64 cells in the assembled 24-volt build...

this morning the cell differential is 19 mV, so it is actively balancing slow but sure... at 5amps ( it started with a 31mV differential )
I contacted a seller of the NEEY 15Amp smart active balancer through Alibaba and they said to contact them on Monday.
at least I got a partial reply....
so maybe I can get an instruction manual vs (not quite sure method)!!!!
super windy but the sun is out so that is a plus for the solar off-grid farm today Saturday >>> April 6th, 2024
have a great weekend!!

 

[michael d]

the NEEY 15Amp smart active balancer :

the NEEY 15Amp active balancer was down to a 9mV cell differential at 2 a.m. this morning....(April 7th, 2024); {{{6mV at 5:52 a.m.}}}
it (the NEEY 15Amp smart active balancer) is balancing fine on the 64-cell build of 8P8S 280Ah Eve version 3 cells in the 24-volt configuration...

I added a battery-positive wire from port 24 to the battery thinking maybe it needed that; so the yellow LED would go away or change but it did not change anything...
when I disconnected the power the timer reset on the NEEY balancer when I reconnected to the Bluetooth app...
The Bluetooth app works great at close distances but the Bluetooth signal does not transmit through walls into my house.... but functions fine outside in the insulated solar power shed...
the status says everything is normal so maybe by guess and by golly I may have it connected correctly...
the "HankzorBMS Store" Aliexpress vendor wrote they would send me the apk for the Android phone but I think I already got that part....it still would be good if it had an actual manual that is better suited for the NEEY 15Amp smart active balancer...
Lots and lots of fierce wind yesterday and some rain late in the day....
April showers are predicted today...
more later....

 

[Steve_S]

I forget if you have a Cell Resistance Tester like a Yaorea YR1035 type of device.
Now that you have it all together and are doing the NEEEY Balancer on there, I am REALLY Curious what the actual cells say in the 4P sets.
Are all the cells in parallel @ same Voltage & IR ? Or is there any deviation in the parallel sets ?

 

[michael d]

I forget if you have a Cell Resistance Tester like a Yaorea YR1035 type of device.
Now that you have it all together and are doing the NEEEY Balancer on there, I am REALLY Curious what the actual cells say in the 4P sets.
Are all the cells in parallel @ same Voltage & IR ? Or is there any deviation in the parallel sets ?

they are in 8P sets.
i do have one of those resistance testers.....maybe later I do that..

 

[michael d]

64 cells 280Ah version 3 cells:

NEEY 15amp smart active balancer at 5mV (April7th 2024)
64 cell build
I have it set to stop at 1 mV maybe should change that to 5mV???

 

[michael d]

NEEY 15Amp smart active balancer >>> each cell being balanced is actually 8 cells in parallel...
that is why I set the 2200 Ah on the neey
I just guessed on that but 280 x 8 = 2240Ah...so close ....

 

[Steve_S]

I have it set to stop at 1 mV maybe should change that to 5mV???

I dunno how much if any gain of any sort is achieved below 0.010. Not likely any gain of any significance but won't cause any harm either.

Sorry, 8P Yes, boy looking at those pics (dunno bout that Chicken Salad LOL) there's a LOT of OOMPH there.
64x 280AH @ 5X "short" Dump: 89,600A dump potential. Talk about a REALLY BRIGHT Flash ! There is a big OUCH lurking there, hehe.

 

[michael d]

I dunno how much if any gain of any sort is achieved below 0.010. Not likely any gain of any significance but won't cause any harm either.

Sorry, 8P Yes, boy looking at those pics (dunno bout that Chicken Salad LOL) there's a LOT of OOMPH there.
64x 280AH @ 5X "short" Dump: 89,600A dump potential. Talk about a REALLY BRIGHT Flash ! There is a big OUCH lurking there, hehe.

the wife likes that chicken salad(convenience food)...I like to reuse the little plastic containers.... they have some stainless steel parts in them and stack nicely...

I am thinking of enclosing it a bit more.... I have some clear plexiglass and was thinking about getting a couple of pieces that can be hinged or removed to prevent anyone from causing a short...
more to be done that is for sure....

yes, 1mV cell differential is a lot to ask.... I may change that back to 5mV and adjust the Soc to 2240Ah on the NEEY...
the wires they provide with the NEEY 15 Amp balancer have the alligator clamps already installed and they are all pre-numbered so that was convenient.
very soft pliable silicone wires... I like that

 

[42OhmsPA]

What voltage are you starting to balance?

 

[michael d]

What voltage are you starting to balance?

26.60 volts (measured via multimeter) in an 8S battery is at the 90 percent SOC...
when I started balancing by the NEEY 15 amp balancer
I turned on the Riden 6024 a couple of times but let the NEEY balance it.
I added about 120Ah via the Riden 6024,after I assembled the 8P8S packafter initial pre-charging during parallel asembly.
when I first started the cells were shipped in about 3.29 volts per cell, and I charged them all to about 3.33 volts per cell with the 3 Riden chargers.

in all reality,,, I think if one had the NEEY 15 Amp smart active balancer going and the pack assembled and the ridens charging at maximum.... >>>> you would not need to do a top balancing at all...
you could just keep upping the ante on the NEEY as you charged the battery all assembled with the Riden 6024....IMO

currently at...>>>
maybe better now as that pic is a couple of hours old

 

[michael d]

64 cells 280Ah version 3 cells:

it is at 26.691 volts with a 5 mV cell differential mas o menos...currently

I have to use my other Android cellular and take a picture of that Android cellular, then email it to my email, download it, then post it on to this forum...

the solar power shed is outside not where this landlock computer is...
I can not type worth a flip on a tiny cellular screen so I prefer to use the old dinosaur desktop for typing things.

 

[740GLE]

You plan to push the cells to 3.45v for a sort of top balance to see how that neely handles it?

 

[42OhmsPA]

26.60 volts (measured via multimeter) in an 8S battery is at the 90 percent SOC...
when I started balancing by the NEEY 15 amp balancer
I turned on the Riden 6024 a couple of times but let the NEEY balance it.
I added about 120Ah via the Riden 6024,after I assembled the 8P8S packafter initial pre-charging during parallel asembly.
when I first started the cells were shipped in about 3.29 volts per cell, and I charged them all to about 3.33 volts per cell with the 3 Riden chargers.

in all reality,,, I think if one had the NEEY 15 Amp smart active balancer going and the pack assembled and the ridens charging at maximum.... >>>> you would not need to do a top balancing at all...
you could just keep upping the ante on the NEEY as you charged the battery all assembled with the Riden 6024....IMO

currently at...>>>
maybe better now as that pic is a couple of hours oldView attachment 207722

From what I understand over the years you are still in the flat part of the charge curve and won't be doing any real balancing; 3.4+V (27.2+V in 8s) is where you should start balancing.

 

[michael d]

You plan to push the cells to 3.45v for a sort of top balance to see how that neely handles it?

Right now I set the Riden 6024 to 26.80 volts and I also adjusted the NEEY 15 amp balancer to 2240Ah Soc....
the NEEY was showing 2mV difference at about 12:30 today (noon).
The voltage an the NEEY and the Voltage on the Riden pretty much follow each other in step....
I do not know if I will go up to 3.45 volts per cell but the NEEY has not blinked at this 64-cell build...
26.8 divided by 8 = 3.35 volts per cell and is at the 99 percent SOC....

I am more inclined to turn the attached 24-volt inverter on and use some of the stored energy....
I am trying to make more appropiate inverter cable now, but it is windy and raining so that is hindering me some also...

 

[michael d]

From what I understand over the years you are still in the flat part of the charge curve and won't be doing any real balancing; 3.4+V (27.2+V in 8s) is where you should start balancing.

they say there are very few Ah from 3.4 to 3.65 but I could push it up higher with the Riden 6024 while balancing with the NEEY 15Amp smart active balancer....

I can always use the power via the attached 24-volt inverter...
right now it is raining and quite windy...

I will turn the Riden up to 27.20 volts in a little bit....
essentially>>>> the Riden 6024 is doing the top balancing with the help of the NEEY active balancer and thus not getting too far out of whack...!!!

 

[michael d]

the Riden 6024 will decrease the amps and the watts will decrease as it gets closer to the battery charging preset value,,,,



I was looking for the correct size cable lugs, (to make new inverter cables) but the rain told me it was coffee break time...(((definitely not a duck but they are out there in my pond happy as can be)))

 

[michael d]

64 cells 280Ah version 3 cells:

I turned the Riden 6024 up to 27.2 volts for battery charging.... at about 230pm on April 7th, 2024...
the NEEY voltage is going up fast also.... and balancing but I do note the cell difference changes a bit more....
cell 8 has always been the cell set with the lowest voltage (((( I likely did not charge them enough as they were some of the last to get a pre-charge before assembly into the 64-cell 8P8S battery ??? ))))



I found cable but not the right lugs so have to order some more cable lugs and will just use the 24-volt inverter as it is hooked up for the moment...