Battery Hookup 280ah 17kw Modules Battery build (16s)

[NewGuyNoob]

I purchased 4 modules from battery hookup to DIY these 280ah for my solar system.

This thread will be slow at first as I am still planning for this build.

 

[Supervstech]

Post pics as items arrive, ask questions as you go.

 

[NewGuyNoob]

The modules are as shown below. I purchased (4)



This is the preliminary design. Each module is over 300lbs and all 4 modules weight in around 1400lbs!



David Poz on YouTube has a great video showing these modules off.

Stay tuned as I figure out how I proceed with these modules to integrate into with my existing off grid solar system.

 

[NewGuyNoob]

These modules have Battery Management Units installed. I can not use these systems for integration.

So therefore, I cut open the BMU and removed the female plug (jack) for the existing BMS leads.

 

[NewGuyNoob]

I purchased these for creating busbars. I plan to attempt to bend/form these for use in the module.




I will create one for the 16s, that leaves 4 prismatic cells left in the pack. Therefore I will create an additional busbar for these units.

With 4 left from each pack I can create another 16s battery back, electrically.

 

[Supervstech]

I purchased these for creating busbars. I plan to attend to bend/form these for use in the module.


View attachment 164657

I will create one for the 16s, that leaves 4 prismatic cells left in the pack. Therefore I will create an additional busbar for these units.

With 4 left from each pack I can create another 16s battery back, electrically.

This material is approximately the same as 4/0 cable. Can handle around 270A

 

[NewGuyNoob]

This material is approximately the same as 4/0 cable. Can handle around 270A

Great! I measured the existing busbars and this is what is already in use.

The Exception was they have a sliver coating and polished at the connection points. I plan to polish and use Belleville washers.

 

[Supervstech]

Great! I measured the existing busbars and this is what is already in use.

The Exception was they have a sliver coating and polished at the connection points. I plan to polish and use Belleville washers.

The coating is there for oxidization protection.
As long as you clean the surfaces you attach to, you should be fine.
It wouldn't hurt to coat the connections with something after they are mounted.
Plastidip, or grease, etc...

 

[Supervstech]

Understanding Bus Bar Ampacity Charts

A brief overview of ampacity charts for both copper and aluminum busbar and how to interpret the data within.

stormpowercomponents.com

 

[NewGuyNoob]

Ok, now I need a good BMS, I’m considering Seplos or Pace/Gobal power’s BMS. Off-Grid garage seems to suggest these are the best from of his testing.

I would like to have communication with XW 6848 Pro and that when fully charged the MPPT’s are not commanded off. (Not sure if a victron only issue)

As of now, I float my cells so I can use power generated by my MPPT’s to carry my existing loads.

Any comments or recommendations?

 

[NewGuyNoob]

OK a bit of progress:

I purchased these from amazon, [I am not an affiliate]:

https://a.co/d/g1rSm3I

Also, I cut some of by copper "buss-bar" so I could use the existing routing of the front battery bracket/design.




I moved the existing connectors over by .75", in the same plane as the orignials. Then cut these out with a 1.5 in hole saw or the terminals.








Now I will have to wait and tackle the electrical seperation of the 4s batteries from the 20s pack. I think I will use 3/0 or 4/0 for this run to the floating negative strapping you can see in the secont to last picture. This factory buss bar, consists with about 50 layers of copper strips, each is very thin and then compressed [cold welded?] together at the ends.

In the last picture, you can see where I cut out about 2 inches of structural reinforcement [square tubing] so I could move these connectors over.

Also, keep in mind this is all mock up "Mark 1". I will recreate this setup 3 more times at least. Then a whole new design for battery #5.

 

[740GLE]

Where did these catl units come from? Some sort of EV?

 

[NewGuyNoob]

Where did these catl units come from? Some sort of EV?

I am not sure, David Poz's Video makes some statments about these being from an abandoned project. I would assume mass storage for a grid system myself. But I do not know.

 

[NewGuyNoob]

Ok I think I have figured out how to complete the 16S of the 20S module.

Here is a semi-mock-up of it.











The module is in 20S configuration. Above is the plan for 16S. I have a pretty good idea as well on a 4S configuration for easy wiring in the near future.

Since I have 4 modules, when I split 4S from each module, I will then have created 5x280 Ah 48V batteries.

I have ordered these insulated bussbar standoffs. I will use these for the central busbar in the pictures.

 

[a619]

Check out this guy who did exactly what you’re trying to accomplish

 

[NewGuyNoob]

Check out this guy who did exactly what you’re trying to accomplish

Thank you for sharing the video! I only found two videos of these cells (modules), this one and David’s.

I’m sure it’s ok the way he has it, but I think I would like to do something a bit different than what has.

I’m hoping to have mine more cleaner looking. Not knocking on the guy of course, I just would like to make it more pretty haha

 

[NewGuyNoob]

Here’s another guy using these modules.

 

[a619]

I waited too long to decide on these and missed out.. From what I have seen, these appear to be brand new, high quality cells.

 

[Supervstech]

Ok I think I have figured out how to complete the 16S of the 20S module.

Here is a semi-mock-up of it.
View attachment 166912

View attachment 166922

View attachment 166923

View attachment 166924

View attachment 166925


The module is in 20S configuration. Above is the plan for 16S. I have a pretty good idea as well on a 4S configuration for easy wiring in the near future.

Since I have 4 modules, when I split 4S from each module, I will then have created 5x280 Ah 48V batteries.

I have ordered these insulated bussbar standoffs. I will use these for the central busbar in the pictures.

View attachment 166927

As pretty as your bars are, and we'll laid out as well... unless you nickel plate them, they will corrode and fail very quickly... you cannot let aluminum and copper come in contact.

 

[Disturbedfuel15]

As pretty as your bars are, and we'll laid out as well... unless you nickel plate them, they will corrode and fail very quickly... you cannot let aluminum and copper come in contact.

This brings me back to my pc water cooling days. I completely forgot about that! Good point. Luckily for OP, nickel plating is not difficult to do via electroplating.

OP, have you decided on BMSes yet? I can't decide which to order for mine, between jk, jbd or Daly. I can't figure out the differences, they all seem to do their job fine. What I think I'm seeing is some BMS interact with specific inverter/chargers better.... Such as Victron.

 

[NewGuyNoob]

As pretty as your bars are, and we'll laid out as well... unless you nickel plate them, they will corrode and fail very quickly... you cannot let aluminum and copper come in contact.

I will tin plate them, I think Tin should be enough? Do you? I will only Tin plate the areas of contact as the remaning area's will have heat shrink on them.

 

[a619]

What's the electrical advantage of using these copper bars for connections instead of just using flexible welding cables?

 

[NewGuyNoob]

This brings me back to my pc water cooling days. I completely forgot about that! Good point. Luckily for OP, nickel plating is not difficult to do via electroplating.

OP, have you decided on BMSes yet? I can't decide which to order for mine, between jk, jbd or Daly. I can't figure out the differences, they all seem to do their job fine. What I think I'm seeing is some BMS interact with specific inverter/chargers better.... Such as Victron.

I will use a DALY 150 [US stock is avialable] for the time being, as I am torn between the Seplos BMS and the updated PC200: Pace BMS P16S200A
Andy's Webiste: https://off-grid-garage.com/battery-management-systems-bms/

 

[NewGuyNoob]

What's the electrical advantage of using these copper bars for connections instead of just using flexible welding cables?

For me it is the mechanical abilty to secure these without a doubt. No Concern, period. No chaffing etc, rub through... loose connection etc..

 

[NewGuyNoob]

Updated Photo's. I am waiting for parts to come in. When that happens the next photo's should contain heat shrink'd bus bars, tinned connections with installed DALY BMS [Temporary]

Or, I wont get that far, time will tell!