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diy solar

diy solar

Build a Battery … Where to start?

I think many think the compression I use is really hard compression but it isn't. It is enough to put pressure on the sides of the cells and also keep them in place.
Yeah, not compression as much as tight fit to prevent swelling and movement.
It looks good, just leave them long enough so it is easy to put the nut on if you ever have to disassemble.
Yeah, will find a way to protect ends so they do not get damaged or cause damage,,

That white foam from the packaging? Get rid of it, it is very flammable. Get some Lexan, you can drill and tap it easy. Plexiglas not as easy. This would give a spot for the screen.
Not packing material. They are flame resistant PVC board.. as everything is a drop hazard I want to make sure I have a few layers of protection. not sure plexiglass would be less or more hazardous.. but will take a look ..
 
Yeah, not compression as much as tight fit to prevent swelling and movement.

(y)
Yeah, will find a way to protect ends so they do not get damaged or cause damage,,

Double nut would work, cut flush with the second nut.

Not packing material. They are flame resistant PVC board.. as everything is a drop hazard I want to make sure I have a few layers of protection. not sure plexiglass would be less or more hazardous.. but will take a look ..
Now that you have DIY a battery, are you prepared to build some more? I did 8 batteries in my shop cabinet.
 
Double nut would work, cut flush with the second nut.
Yes, that's a good idea.. That should protect the threads so prevent unfixable damage preventing taking things apart.. :)
Now that you have DIY a battery, are you prepared to build some more? I did 8 batteries in my shop cabinet.
Yes, but not for the RV.. Although, I liked the entire process.. After we shift from the current house to new location (closer to the water) I will DIY the entire solar system for the house for sure.. I look forward to it .. My problem is I enjoy every part of the process from planning, building, connecting, running and the automation/tracking..

So I like the way to DIY fits perfectly into the bay, and only consideration I would have is to build another just like it to replace the 3xEG4 100ah and have all the batteries in the bay together .. I just like knowing all the parts, the BMS, the settings and how they should/will work together. Nothing against EG4, them batteries have been good to me. I just might have a little addition ..

So YES! Maybe finding a way to record things for YouTube also.. Just seems like I am always in a hurry fighting time, maybe when I retire, but i enjoy that aspect also, i just know once i start, it will not want to stop.. That means full video every week.. Planning, Executing and Editing. Not sure i have the time to do it right :) Someone could make a fulltime job out of this! :/

FYI: Just lost the ability to place panels on ground around RV.. So I may take of a project of mounting to the side of RV? or something that allows easy deploy when traveling, or staying in one place for a while .. I can have as many as i want as long as they are attached to the RV.. hmmmmm
 
When I started there was no real interest is building my own battery. Now, I have this real need to build a battery..

I have a question about sourcing cells, it would appear that you guys all keep up with the latest news and prices where is a good source and what kind of things should I know prior to ordering ?

what BMS do most of you use seems JK BMS but not really sure..

I have seen a lot of material here to help, but not know what is important is like going to google .. just too much data to know the good stuff..

Might build both a 24v for trailer and 48v for RV …

Thoughts?

Congrats on the DIY battery adventure. I'm currently top balancing 32 cells to assemble my two battery banks. When it comes to sourcing battery cells, I found over the past several years that most of the old China sources that seemed trustworthy, or are mentioned in product teardowns of good batteries, now have US inventory vs. praying the boat comes in.

I went with new cells from an existing US DIY battery company, there are many. I'm building a system that needs to last a long time and didn't want to risk saving a buck or two coming from China and have mismatched or questionable cells. I'm not saying throw money away, but if you know how much your product is selling for elsewhere, you can make a decision whether or not to spend a little extra for value like US stock, free shipping, free hardware (fasteners, busbars, spacers, etc.). Since 2021 my experience would be that prices have come down significantly in the past two years.

Over 2 years I've been reading, following, and watching videos from content creators that resonated with me. I have a friend that's a couple years ahead of me in DIY and we talk lessons learned often. I've had large FLA systems in the past (12V, 24V, 48V). You comment there's too much data to know the good stuff. My advice (yeah, another opinion... lol), is that at some point you'll develop a sense of what's BS and what catches your attention as fact because others have shared the same. During this time you may find that all of the different sources of information will have some content that is repeated from different sources, and is based on testing and reviews. That's the good stuff there because you'll have learned enough to recognize when experienced/reputable people are sharing valid information. That's when I felt enabled and knew enough to be dangerous to my checkbook. At some point we all have to take the leap... Imperfect action is still progress!

I've always paid attention to what type of equipment is used for the application, then the brand. I'm migrating from standalone toroidal transformer inverter/chargers to a "hybrid" system that has full bluetooth, WiFi access etc. and not all BMS do that. I also developed a feel for the good, bad, and ugly of BMS land by reading and participating in forums like this one. I even have a couple friends that went cheap and had problems. It taught me to get what worked for my scenario AND seemed to work for others in the same scenario. I'd say JK is on the higher end of configuration customization, but also has a reputation of reliability when running outside a closed loop system (my scenario). Do people report problems? I've never met a human that didn't have some kind of gripe at one time or another.... It does take some technical knowledge to understand and feel confident the settings. BMS at this level aren't really "plug and play." I really liked OverKill Solar and their custom control app, but their next generation high power 48V product is still in development. I also looked into REC remote contactor BMS systems but I didn't see the value in my situation because they can be five times the money. Along those lines, marine applications taught me a TON because they can't fail when your sailboat is in the middle of the ocean.

I guess I'm trying to emphasize that you're probably close to finding and knowing what the good stuff is, maybe start pulling the strings of what you're trying to accomplish, what it's needs are, and see what's attached to "the good stuff" information. The brands and models will expose themselves. When something clicks, you'll say yeah that's the one.

Yes, I talk too much!
 
When I started there was no real interest is building my own battery. Now, I have this real need to build a battery..

I have a question about sourcing cells, it would appear that you guys all keep up with the latest news and prices where is a good source and what kind of things should I know prior to ordering ?

what BMS do most of you use seems JK BMS but not really sure..

I have seen a lot of material here to help, but not know what is important is like going to google .. just too much data to know the good stuff..

Might build both a 24v for trailer and 48v for RV …

Thoughts?

Oh too funny! I didn't realize this was from November!!! BWAH HAHAHAHAHAHAHHAHA
 
Congrats on the DIY battery adventure. I'm currently top balancing 32 cells to assemble my two battery banks. When it comes to sourcing battery cells, I found over the past several years that most of the old China sources that seemed trustworthy, or are mentioned in product teardowns of good batteries, now have US inventory vs. praying the boat comes in.

I went with new cells from an existing US DIY battery company, there are many. I'm building a system that needs to last a long time and didn't want to risk saving a buck or two coming from China and have mismatched or questionable cells. I'm not saying throw money away, but if you know how much your product is selling for elsewhere, you can make a decision whether or not to spend a little extra for value like US stock, free shipping, free hardware (fasteners, busbars, spacers, etc.). Since 2021 my experience would be that prices have come down significantly in the past two years.

Over 2 years I've been reading, following, and watching videos from content creators that resonated with me. I have a friend that's a couple years ahead of me in DIY and we talk lessons learned often. I've had large FLA systems in the past (12V, 24V, 48V). You comment there's too much data to know the good stuff. My advice (yeah, another opinion... lol), is that at some point you'll develop a sense of what's BS and what catches your attention as fact because others have shared the same. During this time you may find that all of the different sources of information will have some content that is repeated from different sources, and is based on testing and reviews. That's the good stuff there because you'll have learned enough to recognize when experienced/reputable people are sharing valid information. That's when I felt enabled and knew enough to be dangerous to my checkbook. At some point we all have to take the leap... Imperfect action is still progress!

I've always paid attention to what type of equipment is used for the application, then the brand. I'm migrating from standalone toroidal transformer inverter/chargers to a "hybrid" system that has full bluetooth, WiFi access etc. and not all BMS do that. I also developed a feel for the good, bad, and ugly of BMS land by reading and participating in forums like this one. I even have a couple friends that went cheap and had problems. It taught me to get what worked for my scenario AND seemed to work for others in the same scenario. I'd say JK is on the higher end of configuration customization, but also has a reputation of reliability when running outside a closed loop system (my scenario). Do people report problems? I've never met a human that didn't have some kind of gripe at one time or another.... It does take some technical knowledge to understand and feel confident the settings. BMS at this level aren't really "plug and play." I really liked OverKill Solar and their custom control app, but their next generation high power 48V product is still in development. I also looked into REC remote contactor BMS systems but I didn't see the value in my situation because they can be five times the money. Along those lines, marine applications taught me a TON because they can't fail when your sailboat is in the middle of the ocean.

I guess I'm trying to emphasize that you're probably close to finding and knowing what the good stuff is, maybe start pulling the strings of what you're trying to accomplish, what it's needs are, and see what's attached to "the good stuff" information. The brands and models will expose themselves. When something clicks, you'll say yeah that's the one.

Yes, I talk too much!

Oh too funny! I didn't realize this was from November!!! BWAH HAHAHAHAHAHAHHAHA
And it was still a good read…yes, your right, I did start to learn the good from the bad.. I sourced from china and got very very lucky with 16 what seem to be perfectly balanced cells.. or it could be my skills of putting everything together .. that’s what I would like top to think anyhow…

No worries and thanks for all the feedback ..
 
Anyone install Axial Fuse On balance leads? I remember reading about it, and now that I am looking back I forgot to do anything with it. Has anyone done it?
 
I am saying there is no point in fusing the balance wires. If then end of one touches something to cause a short it will be while you are attaching them. But you shouldn't have the other end connected to the bms until they are all installed.. so what do they short? I suppose you could pinch a wire later, and in that case short the connection points to the pinch....the wire will melt and probably melt other balance wires....

Add fuses and add resistance to wires detecting tiny imbalances... make a bad crimp make an imbalance.
 
I am saying there is no point in fusing the balance wires. If then end of one touches something to cause a short it will be while you are attaching them. But you shouldn't have the other end connected to the bms until they are all installed.. so what do they short? I suppose you could pinch a wire later, and in that case short the connection points to the pinch....the wire will melt and probably melt other balance wires....

Add fuses and add resistance to wires detecting tiny imbalances... make a bad crimp make an imbalance.
Not sure that was the purpose. The lead got hot, when it melted, then it start a chain reaction of lead to to lead to lead.. I think the idea of the fuse is to stop the cascade fault as soon as possible and stop the wires from starting a fire.
 
Batrium uses fuses on every balance lead. It's a mixed bag, I just swapped out 16 cells and upon reassembly, I see one cell showed a poor connection. I had pulled all the fuses to disconnect after shutting down the Batrium. The problem was the fuse and holder.

Axial fuse crimped into the lead might be a good choice. However with very small AWG wire the wire is the fuse should a short occur. It won't heat and melt most likely, it will just vaporize the wire.
 
Not sure that was the purpose. The lead got hot, when it melted, then it start a chain reaction of lead to to lead to lead.. I think the idea of the fuse is to stop the cascade fault as soon as possible and stop the wires from starting a fire.

I remember the thread, The balance wires were being kept ordered inside a spiral loom and a number if them were damaged and the edge of the board burned off. I do not recall if the source of the problem was found.
 
I remember the thread, The balance wires were being kept ordered inside a spiral loom and a number if them were damaged and the edge of the board burned off. I do not recall if the source of the problem was found.
Yes, that is the one… I’m not sure if it’s worth the extra .. I have not done anything with them as of yet, and debating on if I think it is a good idea or not, if it is how to ensure things end up safer is a better focus. So feedback is welcome,
Batrium uses fuses on every balance lead. It's a mixed bag, I just swapped out 16 cells and upon reassembly, I see one cell showed a poor connection. I had pulled all the fuses to disconnect after shutting down the Batrium. The problem was the fuse and holder.

Axial fuse crimped into the lead might be a good choice. However with very small AWG wire the wire is the fuse should a short occur. It won't heat and melt most likely, it will just vaporize the wire.
crimped little wire leads like that scare me.. has a friend helping and he was doing some crimping and not really ensuring the connect is good…maybe a soldering them? But then how to protect them, Idk, that’s why I am fishing for good ideas.
 
I like the idea of those fuses crimped onto a ring terminal, then crimped onto the balance wire, then covered with (clear?) heat shrink tubing.

Whether you use uninsulated ring terminals and uninsulated butt splices is an implementation detail. Leave enough slack in the wire that you can replace the fuse (and the terminal and the butt splice and the heat shrink) if required.

Nothing wrong with soldering if your skills lead to that and you are not sure about the quality of your crimps.
 
crimped little wire leads like that scare me.. has a friend helping and he was doing some crimping and not really ensuring the connect is good…maybe a soldering them? But then how to protect them, Idk, that’s why I am fishing for good ideas.
30 years ago, I was a solder type of person. Today, I prefer crimps. I had seen wire failures on soldered joints where the solder wicked up the wire. With the crimping tools available today, no way I'd go back to solder.

Even though I have many crimping tools, I bought this one lately and I am impressed. 4 bar mechanism compared to the pliers type I've used for years. I'll still use the one shown here in the video in the shop, the new crimper set goes into the work trailer so I don't need 5 different crimpers on board.

 
30 years ago, I was a solder type of person. Today, I prefer crimps. I had seen wire failures on soldered joints where the solder wicked up the wire. With the crimping tools available today, no way I'd go back to solder.

Even though I have many crimping tools, I bought this one lately and I am impressed. 4 bar mechanism compared to the pliers type I've used for years. I'll still use the one shown here in the video in the shop, the new crimper set goes into the work trailer so I don't need 5 different crimpers on board.

I think I just need a good crimper for smaller wires, the big stuff I love. But I got a nice crimper and buy good lugs. But the small stuff just seems to be unreliable… you say this “one” but it is not linked, and not sure it was named in the video other then snap-on I think?

I am open to the switch as you can see I did on the batter balance leads, but find them frustrating when the crimpers only work 1/2 the time.
 
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I think I just need a good crisper for smaller wires, the big stuff I love. But I got a nice crimped and buy good lugs. But the small stuff just seems to be unreliable… you say this “one” but it is not linked, and not sure it was named in the video other then snap-on I think?

I am open to the switch as you can see I did on the batter balance leads, but find them frustrating when the crimpers only work 1/2 the time.
I bought this one lately
The word “one” is an amazon link. Yes, well hidden.
 
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The BMS leads are so thin that even with a good crimper and ends, there's just nothing to grab onto. After repeated failures on my early batteries with cells just disappearing from the BMS, I learned to strip about twice as much and fold the wire over into the crimp. That gives it enough meat to grab for a good connection. I've never had a cell disappear since.
 
The BMS leads are so thin that even with a good crimper and ends, there's just nothing to grab onto. After repeated failures on my early batteries with cells just disappearing from the BMS, I learned to strip about twice as much and fold the wire over into the crimp. That gives it enough meat to grab for a good connection. I've never had a cell disappear since.
Yes, I have always folded over the balance lead wires before feeding the wire into the terminal.
 

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