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BYD 24v battery packs

iamrich

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I know these are long gone for the most part, but if you happen to have some and are still looking for a solution to the terminals, here is what I did.

I got this idea directly from this video, I just took it a little bit further.


I started out by striping the heatsinks off the top and bottom. They probably made sense in a rackmount battery cage, but stand alone I just don't see the need. This drops about 36 pounds off the battery. I didn't take pics, but it is pretty self explanatory, but here is a how to video


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Pop all the clips off the sides, I started with the negative side (right side?)

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Remove the bus bar bolts:

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I removed the green trace boards as well

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I just broke off the little tabs with needle nose

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You are left with these little screws

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Pop those out, but don't lose them. You will reuse them later.

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Then I moved on to the positive (Left?) side.

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Removed the bolts to the front terminal:

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And then cut it off (this is the most nerve racking part, but there really is no need to worry :)

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Now you can remove the bus bar across the back by taking out the bolts and popping these little plastic clips:

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Bolts are 10mm to break them loose, and then just finish with a screw driver

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Once you remove the back bus bar you are basically done with the right side of the battery. This will now become the back of the battery. The bus bar we just removed was only used to route the negative terminal around the battery to the front which we are no longer using. You end up with this on what was the back corner and this is where you will connect your negative cable.

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Remove the PC board on this side using the same method (needle nose work fine):

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Now take these little square nuts and replace them on the front on the side. It's like BYD already planned this. They must have multiple applications for this battery:

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Now we have to drill two small holes, which is really the only part of this that takes a tiny bit of skill. Use the back bus bar as a template like this:

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Use a bit a tiny bit bigger than the screws (sorry I didn't record the size) and then just push the bolts through to the square nuts and you end up with this:

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Excellent and helpful write-up. I had picked up 4 of these about a year ago and just now started assembling my system. Frankensteining 3 5KW APC rackmount UPS units plus these 4 BYD, my batteries are bulging somewhat and I think it may be best for me to customize the low voltage cut-off value to preserve cycle life. Most likely my powerwall is going to be a mix of storage and a work in progress but what the heck, its mostly a hobby with a payback vs a homeowner plug n play install. I may have to breakdown and buy (shudder) a actual utility connected inverter to qualify for tax incentives
 
Excellent and helpful write-up. I had picked up 4 of these about a year ago and just now started assembling my system. Frankensteining 3 5KW APC rackmount UPS units plus these 4 BYD, my batteries are bulging somewhat and I think it may be best for me to customize the low voltage cut-off value to preserve cycle life. Most likely my powerwall is going to be a mix of storage and a work in progress but what the heck, its mostly a hobby with a payback vs a homeowner plug n play install. I may have to breakdown and buy (shudder) a actual utility connected inverter to qualify for tax incentives
Don't know where you are, but in the US the Federal tax credit program does not require grid tie, just power generation for the house.
 
Finally I embraced the risk and did the mod just removing the terminal rods and modding both sides as I have a setup with all connections in front and I couldn't turn the batteries sideways.
 

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Finally I embraced the risk and did the mod just removing the terminal rods and modding both sides as I have a setup with all connections in front and I couldn't turn the batteries sideways.
Hmmm... I actually like your approach better as it is much less work. (y)
 
Wow, Sir you overdid it, I vote Will sends him an autographed crimper or something for his effort.
What is the weight of the unit all said and done?
 
Wow, Sir you overdid it, I vote Will sends him an autographed crimper or something for his effort.
What is the weight of the unit all said and done?
David poz weighed them at 164lb. Removing the heatsinks and some plastic parts would reduce about 30-40lb
 
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