Jedi new battery finished

[s/v Jedi]

So here it is all assembled and ready to go.

It does not have all the cable ties yet as we need to disassemble it for transport to the boat. The thing is 250 pounds.

This battery is 24V and 10.5kWh. It has 8 Winston 400Ah cells (from Julia Yu) in series. Fuses are 400A for main leads and 30A for balancing leads. The shunt is from a Victron Smart BMV and has it’s own fuse position on the cell8 balance lead.

It was a lot of work; most of the aluminum work was tapping threads in all the crossbars. If it doesn’t bother you I recommend using threaded rods with nuts on the outside instead of the square bar with bolts countersunk for a flush outside.

The big cables and all the heatshrink took some time as well but is unavoidable.

[GreenWave]

This looks and sounds very cool!

[jmh2002]

Oh, now this is going to be a really interesting thread I think. Thanks Jedi

It also looks like a very neat and self contained package. Will this (as we see it) just drop into an existing location onboard?

[Bill O]

Looks great. What small city will you be powering up??

[s/v Jedi]

Originally Posted by jmh2002

Oh, now this is going to be a really interesting thread I think. Thanks Jedi

It also looks like a very neat and self contained package. Will this (as we see it) just drop into an existing location onboard?

Inside our keel are compartments to hold house batteries. This fits inside one with lots of room to spare. The other one still has a Lifeline AGM bank of same Ah capacity but of-course much less usable capacity.

Originally Posted by Bill O

Looks great. What small city will you be powering up??

Our boat came with two 12V 900Ah banks so this one not even replaces that

[Wotname]

Looks good and I am looking forward to seeing pictures once it is installed in the boat.

Minor question - do you prefer cable ties on the small wires rather than using waxed lacing twine?

[s/v Jedi]

Originally Posted by Wotname

Looks good and I am looking forward to seeing pictures once it is installed in the boat.

Minor question - do you prefer cable ties on the small wires rather than using waxed lacing twine?

Waxed twine is what we had to use in school... I believe I never used it after that, although it’s still better I must say the thought crossed my mind but I drilled some holes in the fiberglass for plastic ties so I guess it’s gonna be plastic fantastic

[Palarran]

Looks great. The cables are 4/0?

[NahanniV]

Nice work !

But, it looks like it would be quite a job to access the lower cells. I hope you never have a problem with any of the connections on those cells.

I had one of the cell interconnects on my bank increase resistance after a couple of years, despite being properly torqued and coated with Aluminox.
It would have been impossible to diagnose that problem in situ with your setup.

[s/v Jedi]

Originally Posted by Palarran

Looks great. The cables are 4/0?

Thanks. Yes, the cables are 4/0 gauge and still getting used to the bends and turns

[s/v Jedi]

Originally Posted by NahanniV

Nice work !

But, it looks like it would be quite a job to access the lower cells. I hope you never have a problem with any of the connections on those cells.

I had one of the cell interconnects on my bank increase resistance after a couple of years, despite being properly torqued and coated with Aluminox.
It would have been impossible to diagnose that problem in situ with your setup.

This unit goes inside the keel so any access is limited. When we hoist it up to floor level, I can check the terminals visually and with an IR temperature gun. When anything is wrong, the packs needs to be disassembled, which isn’t too bad

[Wotname]

Originally Posted by s/v Jedi

Waxed twine is what we had to use in school... I believe I never used it after that, although it’s still better I must say the thought crossed my mind but I drilled some holes in the fiberglass for plastic ties so I guess it’s gonna be plastic fantastic

I guess I never left school then!

I sorta like the waxed twine for for small 'fixed' looms or looms made elsewhere and then transported to the site. Some jobs 'shout out' for white twine and others for black

I sure think cable ties are better for large cables say > 8awg

Is the red board a piece of fibreglass or something else?

[Matt Johnson]

Originally Posted by Wotname

Is the red board a piece of fibreglass or something else?

GPO3 -Electrical grade fiberglass

Matt

[more]

nice work. I use QNBBM Lithium Battery Equalizer balancer lifepo4

[Yellowjacket]

Wonderful work, Jedi. Thanks for being a pioneer.

My boat is the little sister of yours, Sundeer 56, with the two battery compartments in line over the keel. Each of my two traction batteries is about 600 amp/hrs, if untrustworthy memory serves, and about 500 lbs.?

How did you calculate for the difference from design weight, since our batteries are part of our ballast? Or is it not significant?