building your own storage rack for server batteries.

[lcram]

I saw a video by Will Prowse using a Dewalt metal rack for server rack battery storage. If you use a metal cabinet or build your own, do you need to buy BUS bars to connect the batteries together and then connect to the inverter? Most server rack storage systems show the batteies horizontal. In the video the batteries were vertical. Can I assume that battery orientation does not affect the operation or life of battery?

 

[timselectric]

I saw a video by Will Prowse using a Dewalt metal rack for server rack battery storage. If you use a metal cabinet or build your own, do you need to buy BUS bars to connect the batteries together and then connect to the inverter? Most server rack storage systems show the batteies horizontal. In the video the batteries were vertical. Can I assume that battery orientation does not affect the operation or life of battery?

Any orientation is fine, except for vent down on the cells.

 

[BarracudaBob]

24" deep is a standard size for storage racks. You never seem to have enough shelves. You would end up buying two and using the shelves to make one unit. Cost adds up quickly. I was looing at Georgia Copper for bus bar material.

 

[shadowmaker]

Got this rack for free when I bought six 10kWh batts. Very flimsy at first but after screwing batts to it made it feel very sturdy. It didn't have busbars so decided to make ones.



I found some hefty copper from local salvage yard for 60e and welded some fasteners to side of that rack. Then made some nylon bushings with my lathe to insulate those bars from metallic frame. Also bought some plastic wireway (~50e) to encapsulate my busbars. Picture below is still missing wireway covers. Maybe not the prettiests but then I was aiming only for cheap and working...

 

[Zwy]

I saw a video by Will Prowse using a Dewalt metal rack for server rack battery storage. If you use a metal cabinet or build your own, do you need to buy BUS bars to connect the batteries together and then connect to the inverter?

I build my own large busbars from 110 copper bar that I nickel plate.

On the left you can see the 1/4" x 1.25" busbar that connects all the 16S batteries inside the box.

Most server rack storage systems show the batteies horizontal. In the video the batteries were vertical. Can I assume that battery orientation does not affect the operation or life of battery?

I prefer standing up. Here is the build thread for my house battery bank.

 

[BarracudaBob]

an interesting point if all the batteries were on their side and the bus bar ran horizontally across the front of all the batteries with heat shrink over the bar sections that were exposed other than terminals. You could fit a lot of batteries on their side on a shelf.

You could potentially screw in the 19-in rack ears to the bottom and top shelf if you had them that close

That's a whole lot of weight on one shelf

 

[LydMekk]

Another vote for leaving cells pointing up with the vent on top.

 

[BarracudaBob]

Will didn't have a problem putting them turned 90 deg, this is the only way to make the rack economical due to number of shelves provided.


I would prefer keeping them up. Anybody find a good inexpensive & strong shelf with enough horizontal shelfs? Batteries are under 8" tall (mine) so you need a lot of shelves 24" deep.

Shelves get expensive quick. Looking at Jakiper & SunGold racks, they don't seem that expensive. Hard to beat the space savings.


The horizontal supports is where it get tricky. Simple rack are readily available.

​

 

[Zwy]

Just buy a pair of ends from Menards, and as many rails as you want. This allows batteries to be vent up.

If you want the cheap stuff and only 3 feet high x 4 feet long, you can go with these end frames and these rails. For the cheap stuff, 4 rails at $32 total, and 2 ends at $46 will get you at least 4 batteries. If you want to purchase shelving, it is $5.79 each. There are taller frames out there too or complete kits and just add more rails.

 

[BarracudaBob]

Just buy a pair of ends from Menards, and as many rails as you want. This allows batteries to be vent up.

If you want the cheap stuff and only 3 feet high x 4 feet long, you can go with these end frames and these rails. For the cheap stuff, 4 rails at $32 total, and 2 ends at $46 will get you at least 4 batteries. If you want to purchase shelving, it is $5.79 each. There are taller frames out there too or complete kits and just add more rails.

• Weight capacity: 2,000 lb per shelf, WOW now you are talking!

 

[Zwy]

• Weight capacity: 2,000 lb per shelf, WOW now you are talking!

I have used the 17" ends with a few rails holding raw steel stock by the metal cutting bandsaw.

 

[mondurr]

I'm looking at just buying a normal server rack with a heavy duty shelf. I need the rack for actual servers and network gear anyway, so I was thinking about mounting the shelf at the top and placing my CALB 180Ah cells on the shelf and then covering the cells with something. I'm going to mount an EG4 12000XP on the wall above the rack. Only issue is I don't think I'll have room to add another shelf if I decide to add another set of cells.

Rack on Amazon
Shelf on Amazon

 

[BarracudaBob]

I'm looking at just buying a normal server rack with a heavy duty shelf. I need the rack for actual servers and network gear anyway, so I was thinking about mounting the shelf at the top and placing my CALB 180Ah cells on the shelf and then covering the cells with something. I'm going to mount an EG4 12000XP on the wall above the rack. Only issue is I don't think I'll have room to add another shelf if I decide to add another set of cells.

Rack on Amazon
Shelf on Amazon

I like the shelf. I already have a similar rack on the left. By the time I put a couple shelfs in it would be pretty expensive. I was thinking if you just put a rack shelf in the back and it was bolted in the front that would be the minim cost. When you pulled a battery out it would slide on the battery below it. Not a perfect idea but it would be budget friendly.

https://www.amazon.com/gp/product/B084CZCGFP

 

[BarracudaBob]

Check out this deal: https://www.amazon.com/dp/B0CSJR2RZB

Or this shelf: https://www.amazon.com/Tecmojo-Anti-Slip-Network-Equipments-Capacity/dp/B0D7VRJ1HC

 

[Rich V]

For racking batteries I think it is best to use 2 central copper plates for +/- terminal connections and then run equal length cables from the batteries to these plates. Connect your inverter cables to these plates with equal lengths. This provides a very easy way to assure you have equal resistance paths for all batteries and avoid unbalanced loading/recharging. Cables are a lot easier to install than bare buss bars in my opinion.

 

[ToddG]

Around here server racks sell for scrap value at auctions.

 

[Wolfpack7483]

Check out this deal: https://www.amazon.com/dp/B0CSJR2RZB

Or this shelf: https://www.amazon.com/Tecmojo-Anti-Slip-Network-Equipments-Capacity/dp/B0D7VRJ1HC

I think I'd opt to pay $20 more & get the one with lockable wheels: https://www.amazon.com/dp/B0CY24KZD...?sp_csd=d2lkZ2V0TmFtZT1zcF9ocXBfc2hhcmVk&th=1

 

[Wolfpack7483]

On 2nd thought, I'd have concerns with their stated load bearing capacity of 260#

 

[BarracudaBob]

On 2nd thought, I'd have concerns with their stated load bearing capacity of 260#

4 x 100lb rack batteries would put a hurtin' on those wheels.

My frugalness is kicking in. How about a couple Harbor Freight furniture rollers to get them off the floor. Face them up and have a piece of metal run down the rack ears to bolt them together. Maybe put a cover or Lexan over the top for dust. That will Probibly be my temporary idea until something more permeant.

 

[Wolfpack7483]

The 260# capacity is without wheels. These are the wheels I put on my current "dolly" with 3 batteries. Says they are rated for 150# ea and 450# for 4 together.
https://www.amazon.com/dp/B085MGHVB3?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1

 

[mondurr]

Yeah pay attention to the weight rating on those racks and shelves. The shelf I linked previously will hold 250lbs, although it also says 330lbs, but I'll stick to the lower amount. I'd go the Dewalt shelving route if I didn't have deep servers to mount.

 

[BarracudaBob]

Buy a heavy duty shelf, put the shelves' closer to each other and cut it shorter (in my case) and lay the batteries on it. K.I.S.S.

https://www.amazon.com/dp/B0CT38CCX3

OR

Home Depot