ripple4
Posts: 82
Joined: Tue Sep 18, 2018 1:45 pm
Delivery Date: 18 Sep 2018
Location: Toledo, Ohio

Re: 5000w hybrid inverter for grid assisted solar charging

Tue Jul 09, 2019 5:30 pm

I like that guys' videos, i had not seen that one yet, good stuff.

Doing what he did for a 48v 200ah lifepo4 battery would be very cost prohibitive, a much easier, faster option would have been to buy 8x 100ah 12 LIFePo4 batteries and gang them up, they already have a BMS and are rated for higher peak current draws. for example, the so called mighty max on amazon has 12v 100ah batteries, 8 of which would recreate what i have here with much less effort, at $30/ah/48v. the other option would have been the 30x of the 3.2v 100ah brick cells at $23/ah/48v. this setup i'm working on should be $9/ah/48v, but its so much more work. lead acid is cheaper up front, i learned, but has 1/3 the life, so it ends up costing 2x as much if the time period is long enough.

avoiding imported parts is a nice goal, my leaf was made in asia, so i'm not off to a good start, right. In general its very hard to find the exact part domestically made at all, let alone for a competitive price. often I give the imports a shot, and if they don't work go premium on that item. there are many layers of protection to get refunds on imported parts that fail, esspecally from good market places like amazon, and as a last resort, credit card charge backs.

BrockWI
Posts: 798
Joined: Fri Mar 28, 2014 6:28 am
Delivery Date: 28 Mar 2014
Leaf Number: 423875
Location: Green Bay, WI.
Contact: Website

Re: 5000w hybrid inverter for grid assisted solar charging

Wed Jul 10, 2019 6:08 am

He gets those 18650 for real cheap somehow, I haven't watched all his videos, but I know he gets a few dud and has to check them all and find the good ones.

I know when my 400a @ 48v bank of L16's goes I am switching to Li and be done with lead acid :)
3 kw solar pv - XW6048 - eight L16's
4 ton GSHP - 1 ton ASHP
2003 VW TDI 200k miles - 52 mpg lifetime
EVSE level 2 - Clipper Creek HSC-40
2013 S model with QC package Mar of 2013
lost first bar @ 72k
@90k miles - 54.71Ahr - 83.64SOH - 78.44Hx - 237GID

ripple4
Posts: 82
Joined: Tue Sep 18, 2018 1:45 pm
Delivery Date: 18 Sep 2018
Location: Toledo, Ohio

Re: 5000w hybrid inverter for grid assisted solar charging

Sun Jul 14, 2019 1:10 pm

New inverter and new MPPT installed, also there are only 12 of the 30 battery modules to go, the end is in sight! the epever MPPT is the 200v 100a version with auto-generator start. This USA-made inverter and highly-rated MPPT update cost 4x what the original 3-in-1 box cost, but based on the weight, its 3x times heavier too (22lb vs 73lb) in that dollar per pound perspective, its close I guess!

Image

ripple4
Posts: 82
Joined: Tue Sep 18, 2018 1:45 pm
Delivery Date: 18 Sep 2018
Location: Toledo, Ohio

Re: 5000w hybrid inverter for grid assisted solar charging

Sun Jul 21, 2019 5:13 am

this is what i came up with for the battery wiring. i used automotive 10awg wire becuase the insulation is soft and easy to work with. this connects 8 cells together, and then i have 4 of these wires parallel. each 10awg conductor can conduct 30amps, so that's 120amps continuous current flow. which i figure is less than the 110amps DC 48v the 4400w inverter will draw at full power.

i put the little glass fuses on each cell so that if i shorted it out, it would not cause a fire. the cells were very hard to spot weld to i'm not really sure what black magic goes into getting strong spot welds on these because i have a good spot welder and even with 2,000amps the first weld was the only strong weld, after the first weld the second and third welds were weak and i can pull the nickel strap off with my bare hands.

the soldering is not easy either. the metal of the battery sucks the heat out of the iron, and the smooth finish of the cell metal prevents solder (88pb10sn2ag) from sticking, so hitting it will a stone or sanding drum got the solder to stick, but it took two irons at full power to flow the tinned solder around the fuse leads. but once its on, i cannot pull it off. on the negative side i used a small U shaped bare tinned copper 16awg wire to connect the cell to the 10awg wire.

then once i have these all done, i'll use 30amp rated terminal strips to connect each of the 4 + leads to the next modules 4 - leads. that way if i ever want to i can easily rewire it to 12v or 24v. also the BMS wiring will be really simple since all connections are pulled out on terminal strips. it would have been alot easier to buy 4x $900-1500 12v 200ah lifepo4 batteries and just used 3 jumpers to hook it up, this way i'm showing is not the easy way to do it.

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LeftieBiker
Moderator
Posts: 13442
Joined: Wed May 22, 2013 3:17 am
Delivery Date: 30 Apr 2018
Location: Upstate New York, US

Re: 5000w hybrid inverter for grid assisted solar charging

Sun Jul 21, 2019 1:52 pm

The folks at endlessphere.com should be able to help you with the connection welding or soldering. There are a LOT of pack builders there. One example:

https://endless-sphere.com/forums/viewt ... 14&t=68005
Scarlet Ember 2018 Leaf SL W/ Pro Pilot
2009 Vectrix VX-1 W/18 Leaf modules, & 3 EZIP E-bicycles.
BAFX OBDII Dongle
PLEASE don't PM me with Leaf questions. Just post in the topic that seems most appropriate.

ripple4
Posts: 82
Joined: Tue Sep 18, 2018 1:45 pm
Delivery Date: 18 Sep 2018
Location: Toledo, Ohio

Re: 5000w hybrid inverter for grid assisted solar charging

Mon Jul 22, 2019 7:27 pm

Lots more to learn, thank you!

Oilpan4
Gold Member
Posts: 946
Joined: Wed Jan 09, 2019 10:51 pm
Delivery Date: 10 May 2018
Leaf Number: 004270

Re: 5000w hybrid inverter for grid assisted solar charging

Fri Jul 26, 2019 2:03 am

Next time I mess with LiFePO4 cells I'm going with 50 or 100ah cells, assuming that the pack is going to be that big.
1st and 2nd battery was 18650 cells, my 3rd battery amp20 prizmatics.
I liked working with the big cells a lot more.
Not messing around with a bunch of little batteries any more.
2011 white SL leaf with 2014 batt.
Chargers: Panasonic brick moded for 240v, duosida 16a 240v and a 10kw setec portable CHAdeMO
Location: 88103

LeftieBiker
Moderator
Posts: 13442
Joined: Wed May 22, 2013 3:17 am
Delivery Date: 30 Apr 2018
Location: Upstate New York, US

Re: 5000w hybrid inverter for grid assisted solar charging

Fri Jul 26, 2019 3:34 am

LifePo4 is also a very stable chemistry. The only drawback is the relatively low energy density.
Scarlet Ember 2018 Leaf SL W/ Pro Pilot
2009 Vectrix VX-1 W/18 Leaf modules, & 3 EZIP E-bicycles.
BAFX OBDII Dongle
PLEASE don't PM me with Leaf questions. Just post in the topic that seems most appropriate.

Oilpan4
Gold Member
Posts: 946
Joined: Wed Jan 09, 2019 10:51 pm
Delivery Date: 10 May 2018
Leaf Number: 004270

Re: 5000w hybrid inverter for grid assisted solar charging

Fri Jul 26, 2019 7:06 am

It's cheap and doesn't contain the slave mined environmental disaster known as cobalt.
2011 white SL leaf with 2014 batt.
Chargers: Panasonic brick moded for 240v, duosida 16a 240v and a 10kw setec portable CHAdeMO
Location: 88103

ripple4
Posts: 82
Joined: Tue Sep 18, 2018 1:45 pm
Delivery Date: 18 Sep 2018
Location: Toledo, Ohio

Re: 5000w hybrid inverter for grid assisted solar charging

Sat Jul 27, 2019 5:16 pm

I agree that the ever popular 18650 is a non-starter. after testing 5-6 different kinds (no *fire ones either, branded ones) none of them could provide more than 1.5ah with the limited voltage ranged needed for long life. the really large format cells can be a value, I always am on the lookout for 30ah+ deals, but if you make a chart with cost on the y axis and (real) amps hours on the X axis, the minimum point was these 32700 cells. if someone can link to a 48v/200ah/2000+cycle battery for even close to the $1800 this method cost, that's good info to get in this thread, please share.

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