Self build in Lincolnshire…..

[Lincs Robert]

And typically I can’t find the lugs supplied with the unit. The manual describes them as M6, so I’m assuming a M6 lug with a 6mm hole? I’m torn between buying the £10 crimp tool you hit with a hammer, or a £27 ish hydraulic crimper which seems a lot more elegant for just a little extra.
Rob

The terminal size needed is for 25 sq mm cable with an M6 (6mm) hole. The switch fuse uses 25 sq mm M8 (8mm) terminals IIRC (I can go and check in the morning).

The hydraulic crimp tool is one heck of a lot better and more reliable to use than the hammer type, as it will form a proper hex shaped crimp all around the cable. I have had one of the cheap Chinese made hydraulic crimp tools for many years now, it's never missed a beat.

Thanks - I’ve downloaded the spec on the switch/fuse & its M8 as you say. I’ve just ordered the hydraulic crimper as well - the hammer one looks ok - but I’d probably do myself a mischief using it!

[Oldgreybeard]

Good to know that my ageing memory cells still seem to be OK at remembering things like terminal eye sizes!

[Lincs Robert]

Good to know that my ageing memory cells still seem to be OK at remembering things like terminal eye sizes!

Ha ha, I’m with you on that one. I can remember config information on equipment I worked on 40+ years ago, but ask me what I had for breakfast & I’d struggle to remember……..

[Lincs Robert]

Ok, so here’s the update after a couple of weeks radio silence.

4 of my 10 Pylons have now gone - thus funding the purchase of the second Chinese Stack. I’ve asked Colin for a quote and will get that ordered ASAP.

It’s a crazy time of year to have your battery capacity reduced by 40%, but needs must I suppose.

I’ve cleared space for the new stack(s), done my structural woodwork and taken delivery of the Frankenstein DC breaker/fuse. I think I’d better get another one on order pretty sharpish. Active cell equaliser is ordered, and I’ve now got my crimps & hydraulic tool ready & waiting to be put to use. I’ve also constructed the plywood end caps for the banks of 5 cells and collected the threaded studding, wingnuts etc. Would a 3mm thick hardboard spacer suffice for going between cells? I’m assuming that when the cells/spacers/plywood caps are assembled that the wingnuts are then “gently nipped up” tightness wise?

Next steps are to get the 25mm DC cables ordered up and the Frankenstein switches wired in - I can do all that prior to my big deliveries arriving.

Am I right in assuming that the capacity of my target configuration will be 13.44 + 13.44 + (2.4 x 6) = 41.28 kWh. Less a bit I suppose for the Pylon reserve 10%, or a tad less than 40kWh overall. That’s a 17kWh increase in capacity above when I had my 10 Pylons, funded pretty much by the reduction from 10 to 6 Pylons.

Cheers- Rob

[Joeboy]

Ok, so here’s the update after a couple of weeks radio silence.

4 of my 10 Pylons have now gone - thus funding the purchase of the second Chinese Stack. I’ve asked Colin for a quote and will get that ordered ASAP.

It’s a crazy time of year to have your battery capacity reduced by 40%, but needs must I suppose.

I’ve cleared space for the new stack(s), done my structural woodwork and taken delivery of the Frankenstein DC breaker/fuse. I think I’d better get another one on order pretty sharpish. Active cell equaliser is ordered, and I’ve now got my crimps & hydraulic tool ready & waiting to be put to use. I’ve also constructed the plywood end caps for the banks of 5 cells and collected the threaded studding, wingnuts etc. Would a 3mm thick hardboard spacer suffice for going between cells? I’m assuming that when the cells/spacers/plywood caps are assembled that the wingnuts are then “gently nipped up” tightness wise?

Next steps are to get the 25mm DC cables ordered up and the Frankenstein switches wired in - I can do all that prior to my big deliveries arriving.

Am I right in assuming that the capacity of my target configuration will be 13.44 + 13.44 + (2.4 x 6) = 41.28 kWh. Less a bit I suppose for the Pylon reserve 10%, or a tad less than 40kWh overall. That’s a 17kWh increase in capacity above when I had my 10 Pylons, funded pretty much by the reduction from 10 to 6 Pylons.

Cheers- Rob

Well done! I used a black plastic sheet between the cells. Just a builders sheet on a roll that I had in a shed. Isolates them in case. I bought my 25mm2 cables from Ebay. Do you want a link?

I ran my retaining rods up then nipped them up. Although I was doing vertical lifts so needed them as one. If you are building at floor level I think run up handtight then a 1/4 turn would suffice.

Your capacity estimate looks good, exciting times!

[marshman]

3mm might be too thick for the spacers to allow the standard connecting straps/links to be used without opening out the holes. Sure I read somewhere a max of 0.5 to 1mm.

[Lincs Robert]

Ok, so here’s the update after a couple of weeks radio silence.

4 of my 10 Pylons have now gone - thus funding the purchase of the second Chinese Stack. I’ve asked Colin for a quote and will get that ordered ASAP.

It’s a crazy time of year to have your battery capacity reduced by 40%, but needs must I suppose.

I’ve cleared space for the new stack(s), done my structural woodwork and taken delivery of the Frankenstein DC breaker/fuse. I think I’d better get another one on order pretty sharpish. Active cell equaliser is ordered, and I’ve now got my crimps & hydraulic tool ready & waiting to be put to use. I’ve also constructed the plywood end caps for the banks of 5 cells and collected the threaded studding, wingnuts etc. Would a 3mm thick hardboard spacer suffice for going between cells? I’m assuming that when the cells/spacers/plywood caps are assembled that the wingnuts are then “gently nipped up” tightness wise?

Next steps are to get the 25mm DC cables ordered up and the Frankenstein switches wired in - I can do all that prior to my big deliveries arriving.

Am I right in assuming that the capacity of my target configuration will be 13.44 + 13.44 + (2.4 x 6) = 41.28 kWh. Less a bit I suppose for the Pylon reserve 10%, or a tad less than 40kWh overall. That’s a 17kWh increase in capacity above when I had my 10 Pylons, funded pretty much by the reduction from 10 to 6 Pylons.

Cheers- Rob

Well done! I used a black plastic sheet between the cells. Just a builders sheet on a roll that I had in a shed. Isolates them in case. I bought my 25mm2 cables from Ebay. Do you want a link?

I ran my retaining rods up then nipped them up. Although I was doing vertical lifts so needed them as one. If you are building at floor level I think run up handtight then a 1/4 turn would suffice.

Your capacity estimate looks good, exciting times!

Thanks, you put the link in your thread somewhere & I’ve already used them for lugs etc

[Lincs Robert]

3mm might be too thick for the spacers to allow the standard connecting straps/links to be used without opening out the holes. Sure I read somewhere a max of 0.5 to 1mm.

Good thinking - thanks

[Lincs Robert]

3mm might be too thick for the spacers to allow the standard connecting straps/links to be used without opening out the holes. Sure I read somewhere a max of 0.5 to 1mm.

Good thinking - thanks

And I’ve just had a rummage around and found something suitable of the correct thickness. I was putting off cutting up the hardboard, I always find it messy stuff to cut anyway. Thanks again for the heads up

[nowty]

Am I right in assuming that the capacity of my target configuration will be 13.44 + 13.44 + (2.4 x 6) = 41.28 kWh. Less a bit I suppose for the Pylon reserve 10%, or a tad less than 40kWh overall. That’s a 17kWh increase in capacity above when I had my 10 Pylons, funded pretty much by the reduction from 10 to 6 Pylons.

Cheers- Rob

Sounds correct to me and you've just pushed the secret list to over 3.3MWh of energy storage.