diy solar

diy solar

96 Cell A123 ANR26650M1B on FleaBay for $99 Shipped. Tested 100% Amp Hours and 98% Watt Hours. Cut Into 12V Packs And Slides Into 30 Cal Can

MarcoWasRight

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Aug 22, 2022
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So I picked up one of these electric bus modules. After recently getting screwed on eBay with some Headways I wasn’t very optimistic but the price was too good to pass up since the seller was guaranteeing 90% capacity. At a 3A load (Sorry only have a DL24 and didn’t want to push it to 4A) I got 100.1%/97.9% on the first discharge. Second discharge was 100.5%/98.1% (Ah/Wh). First test was around 3.58V to 2.5V. The second discharge was 3.60 to 2.55V. Pack is fairly well balanced, I did just a little work in two groups that. The pack was shipped at 39.6V so just shy of nominal 3.3V.

The most popular use of these packs is to keep 3 whole and chop up another one to add the 12V blocks to the full ones for a classic 16S LiFeP04.

My mom has been complaining about not having enough light for cooking when my parents go glamping with their friends so I was originally going to build a 4S pack out of LG MJ1’s to power a 70W COB LED panel through an XYS3580 but I didn’t like the thought of giving my mom Lithium Ion even if I was going to put it in a metal box. I’ve had the can for a couple weeks ($15 Harbor Freight) and something told me I could squeeze a 12V M1B pack in it.

Looks like if I use the middle pack or chop off the spot for the bus bar on this end piece it will slide right in. Using a granola bar box to simulate the thickness of some epoxy resin board I have still packed away in a box. My plan is to use one of these 4S8P packs to power the buck boost converter in the lid of the can. The XYS3580 has been a really user friendly way of safely powering a 7000 lumen floodlight down to much more manageable levels. I’ll likely adhere the LED panel to the outside of the ammo can and look at putting a layer of clear acrylic over it. I’ll route the wiring into the can using some rubber grommets that are oversized so if a cell vents it has at least two holes to escape.

Just thought I’d share this perfect fit with you guys. When I’m done with cutting up the pack I’ll mount the middle third into the can and take a stab at mounting the converter in the lid. Still need to order some thermal pads and/or thermal tape to secure the LED to the can.
 

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A word of warning for anyone attempting this. When you cut the pack into thirds you will find the outermost cells are not going to be attached by much in regards to the tab that goes on the pos or neg of the cell. In order to make this fit I am afraid I'm really going to have to trim down the nickel and I'm not sure I want to go that far. Without using any kind of insulation the pack *might* fit while leaving a decent amount of nickel for those tabs to stay connected but that's obviously unacceptable.
I finished cutting up the pack today and making all the edges dull(er) but I'm still struggling to fit the pack into the can with cardboard insulation. I don't think the epoxy resin board I have is any thinner and I think barely paper (fish paper) could possibly tear.
Can I get it to fit? yeah but barely
 
For anyone wondering the middle 12V pack does indeed fit. I was not happy about taking that much nickel off but the pack is going to have quite a tight fit once I switch to expo y resin board and some kind of space filler for the long wall (pack is about half an inch skinnier than the can).

Pulled out my salvaged epoxy boards and sweet baby Jesus are they hard to clean. Adhesive on them only broke down when I pulled out the 99% iso. Running a 70W COB LED panel on another pack just to make sure it will run as long as I think it will. The thermal adhesive tape is on the way, hope it works well because the little experience I have with thermal paste was disappointing in the adhesion department. Using a buck boost module (going to use the Drok XYS3580, not the ZK4X or ZK5X) to run the light down to 11V or potentially down to 10V if there was an emergency and a few extra minutes were needed. Might put the USB PD & QC socket on the can as well if there is room, not sure about that one. As much as I like a multi tool this thing is only 20Ah and it has one primary job and one backup job. The backup job is too important to have everyone and their mom trying to use this can, more about that below.

My final thought is to add some big Terminal studs or binding posts (larger than M8) to the lid or side of the can for emergency high amperage 12V. Jumpstarts, running the winch, running the air compressor, super chilling the alcohol by running the 12V fridge/freezer hard. I’ve seen 4 A123 26650 cells in series start a small car so I feel pretty confident a 4S8P pack could cold start a large gas truck.
 

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