I didn't mean to overly confusing before, but this is a great topic that I just seem to cover with others all the time.
On straight batteries, no BMS
- Rated capacity is the difference between min low and max high for any given cell.
- Operating capacity is what range you choose to use on the bottom end and the top end of your cycles.
- sometimes operating capacity can also be referred to as DOD or Depth of Discharge
If you need 5 kWa for your project.. You don't really go out and buy a 5 kWa rated battery.
- at 90% Depth of Discharge, you need look at 5.5 kWa capacity
- at the 75% target usage you would need a 6.6 kWa capacity
- at the 50% target usage you would need a 10 kWa capacity
The reason why you genrally want to operate with the smaller possible DOD window is because it keeps the cells healthy and happy. This gives them a longer life.
Just attaching up a inverter and solar charger to your battery pack is going to get you 85%-90% of the rated capacity of raw battery packs from day one. Inverters generally cut off way before you get close to the bottom end of the range. Solar Chargers tend to tapper off before they hit the top end. To reduce your DOD, you would increase the cut off point on the inverter and decrease the top end on the solar charger.
Batteries with onboard BMS are different...For those you should be seeing the capacity range locked in by the BMS in the product.
In the recycle battery world... you will see a range of capacities over similar types of cells. Historically we have always gone with a 80% rated range over a large number of cells. There is like this bell curve that develops.. The cut off is basically 80% of the top of that bell curve.
This also ties into the important topic of cell matching when using individual cells make your own battery pack. The weakest link on a battery is the lowest cell in the series. If you need to build a 12S battery, you do not go out and buy 12 used recycled batteries. You really should get something like 15 of them. You set aside your weakest ones and use the best 12 of the 15 to build with.
When any battery has a single weak cell in them, their real world capacity takes a nose dive. It's not all the cells. It only just takes one in the series.
Hint... if you really want bargain basement recycled battery cells, look for crappy underperforming cell packs that are no longer usable for their original application. Two things generally happen. The cheap BMS inside is burnt out or a single cell has crapped the bucket. The end result is that the pack is no longer usable but 9 times our of 10 the vast majority of the cells are still health. Examples are laptop battery packs, tool packs, and 12v lithium battery packs that look like car batteries. That's when your build your own packs and installing a BMS from scratch.