Building a Custom 48v LiFePO4 Battery

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Welcome to our channel! We’re excited to get into this with you guys and share some of our journey and knowledge of custom van conversions & Offgrid Power.
In this video, we're building a custom 48v battery for a customer. This is one of our biggest builds to date. This battery turned out great and we're stoked with how it turned out!
If you’re building out a van and need help, get in touch: geni.us/offgri...
If you're not sure where to start with your Offgrid Power set-up, book a consult call with us: geni.us/offgri...
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[@sparkfire1223]

Will they not leak being on the side? How many can you stack before weight is an issue??

[@BradCagle]

Sweet battery build! Only thing I would suggest is to route the BMS sense wires away from the other battery terminals. Also i've used those little busbar terminals like you have, I don't think they are very good, mine get rather hot at just 100a

[@offgrid_power]

Good points. Thanks!

[@SkypowerwithKarl]

If that threaded rod rubs through the shrink wrap of the battery case, things will get very exciting. Slide some hose over them. Fixturing is a good idea as long as the pressure is maintained and not over 12 psi regardless of state of charge. Solid buss bars and vehicle vibration can be problematic for the terminal bases and loosening connections. See Digital Mermaids flexible buss bars

[@andrewhofmann5453]

Agreed, with enough tension on the bars, the cells may never move but safety and perception are gold here. Overall, i love the build.

[@patrickmckowen2999]

I seen in another build the put plastic tubing on the rods Cheers

[@BradCagle]

I zoomed in, looks like they have clear tubing on the rods.

[@medicinemom3620]

Why do you habe the BMS attached to another bus bar?? And can that second bus bar be used to make any connections? Just learning about all this!

[@raeesstemmet9656]

Great vid guys. Straight to the point. Nice looking battery

[@MacMcCabe2456]

Any suggestions for building a 100 AH 36 volt golf cart battery for my ezgo golf cart ? Thanks, great videos !

[@Mike-01234]

I'm learning about building batteries trying to understand how it works. BMS which I have found seem to be rated at 100, or 200 amps then they have a max voltage usually up to 48V. The batteries you have are 300AH capacity batteries your BMS in this build I see has a 200AH rating. How does that work?

[@offgrid_power]

The battery capacity and BMS maximum continuous discharge current are two different things. The 304Ah batteries have a capacity of 304Ah, which means (for example) they can be discharged at 304A for one hour to deplete completely. But the BMS has a maximum continuous discharge current of 200A.

[@dino5002]

thanks for your video. why does the system show 20v when its turned off?

[@krishnendupatra7602]

It would be very helpful if you could provide the size or any link of the long steel bolts that you used

[@jamesleavenworth4312]

I like to cover the tie bolts with sink tube. There should be a plastic sheet between the cells. The blue film protect from shorting out. It is delicate. Otherwise pretty nice build!

[@offgrid_power]

Thanks for the suggestion!

[@learningtogether1902]

Nice i have a 48v byd lithium batteries they came in two pairs 24v each which are in series making up to 48v but the problem is that i misplaceed the bic card which means that i cant used it I need help on how to build my own bms in both packs.

[@nielsdelrue7242]

dear your video is very helpful. could you guys answer my question so i can start working on my battery without being sure it will work for what i need? I build a houseboat and will build 1 to live on and will build 3 to sail with a vetus e line 100 electric motor now my question is can a 10kw motor run on such a battery?

[@dashley2525]

All that trouble top balancing and don't you know the BMS has a passive balancer which is not capable of keeping the cell balanced. Daly now sells an active balancer for this reason with a special Y cable to hook it up in parallel with the BMS. If you thought the BMS could passive balance, why top balance anyway? Keep you fingers crossed and hope for the best I suppose.

[@patrickmckowen2999]

Fantastic build 👍 I'm looking to build same size pack and tiring to figure the box that will go onto a dolly with an inverter making it mobile from cargo trailer camper to house. Cheers

[@andrewhofmann5453]

I have heard different approaches to attaching the balance leads, most people say that threading the bus-bars and tapping them there is better than adding them to the posts. Any feedback or preference to others out there?

[@bryanmendoza2770]

since this is for RV, it is expcted on the move and there is no cushion between those battery cells. is that ok?

[@Mazlem]

Many companies are putting thin sheets of plastic or foam between and around the cells for added protection. It's good practice.

[@offgrid_power]

It's very unlikely that it will be a problem without it, but we do put thin layers of padding between the cells on bigger batteries.

[@chuksobi593]

hey just a quick question, how many solar panels and which configuration do I need to fully charge a 40kwh lifepo4 power bank, in my country we do have 8 to 9 hours of sun everyday...

[@madvlad1]

The European Commission has a fantastic tool on their website that will help you model average irradiance based on your location and help you understand how much installed capacity you'll require throughout the year: re.jrc.ec.europa.eu/pvg_tools/en/

[@TheJensss]

Nice build! What brand is thees LiFePo4 cells and what are the material cost of this battery without the labor? I'm planning to build a 250kW solar system on my farm in the next years, so I would need over 100 kW of battery storage to take full advantage of all the solar panels. That means that I would need 8 similar battery packs :P

[@madvlad1]

They're EVE cells. For a system of that magnitude, I'd suggest you're not going to be using a 48V system. At nominal voltage, that kind of power output would be producing thousands of amps of current, which is impractical to work with. You'd be certainly looking at something industrial or bespoke to handle that kind of power.

[@TheJensss]

@@madvlad1 Thank you. I would really like to use the Victron ecosystem for this setup, so voltage depends on what is supported by Victron. I think the best setup would be 3X of the largest Victron Quattro units to get 3 phase power at 230V on IT network which is standard in my area. Since victron only has "small" MPPT charge controllers, we are looking into the Fronius charge controllers. Since they should work with Victron, and are made for larger arrays. Keep in mind that I live in Norway where we have very little sun in the winter. So the solar array would be massively oversized for the summer, but just enough in the winter. Panels have gotten cheap and I noticed that there are a huge discount for buying a shipping container with panels, so since I got the space. Why not? 🤷😜

[@madvlad1]

@@TheJensss Love it! If you've got too much summertime capacity and have to scale up for winter, and you don't have a grid feed in option, you could always just disconnect strings to reduce the current in the summer too - that could be an option. The Victron ecosystem is really nice - and yeah having 3P will be really cool, especially if you have some heavy inductive loads. Have you considered server rack 48V batteries?

[@TheJensss]

@@madvlad1 Our farm is connected to the grid, and we already have 3x 200amp intake fuse, so in the summer selling the excess power would be the best option. If I need more power output, I can connect 6x Victron Quattro units for total of 90kW of output. But since we only use about 40kW at max load, 3 units should be fine to start with for our usage. Maybe a separate and larger inverter could be used as a dedicated inverter for selling the power to the grid? I almost forgot to mention that there is a “special” tax rule in Norway, that limits power output to the grid to 100kW. If overstepped, you would be counted as a commercial power plant and would have to pay wayyy higher taxes on the power you sell. This does that I plan to spread the solar array to 3 different angels, to spread the power production through out the whole day. Yes, I have looked into server rack batteries, and they look awesome. But when you are comparing them to a self-built battery like the one in the video. The price to kWh is not that great, especially when the battery is in the size of 100 kWh +. The reasons we want a large battery is mainly to be able to support large loads without taking damage, and additional advantages is that we can charge the electric car full from the solar battery. And in case of a power outage the farm would also have a large backup power source. Long power outages never happen, but since we got animals, I think it is smart to prepare for such situation. Now we just have a generator on the tractor as backup… I have always had a dream about being self-sufficient with power since we only use electricity with heat-pumps and wood, to heat our house in Norway. This is because electricity always has been cheap, so there has never been a need to use gas for cooking or heating. But when the energy crises started the project became way more relevant the last 2 years. Since power usually costs about 0.02 - 0.03 £ pr kWh and now it costs 0.4 - 0.7 £ pr. kWh because of the war and Norway is selling all the electricity to the EU…. So obviously solar is way more relevant when the power costs 1200-2000% more compared to 2020 and before.

[@patrickmckowen2999]

@@TheJensss Also check out www.youtube.com/@RayBuildsCoolStuff/videos Cheers

[@oneshot_onekill4618]

Do you have a link for the cells you have?

[@offgrid_power]

Here are the cells: geni.us/EVE304AH

[@realeyesrealizereallies6828]

That will have to be two guys dropping that battery in, as I doubt that more than that will fit into the space..Putting the all thread inside of some pex water lines is a good idea always, but especially for that build, if those cells move because of being bounced around in a vehicle everyday, and rub up against that all thread, it only has that thin blue material to rub through before it shorts out, the pex won't allow that to happen ever..

[@gregcope5565]

In the last segment, are the cells not upside down (by looking at the BMS cables)?

[@Mazlem]

They are, but the very last shot shows it sitting upright with the BMS facing up. and that's how it'll be installed, which means the cells will be sitting on their side. Most batteries have the cells facing upright but on their side is ok too.

[@ivaylomanolov1455]

Won't the batteries have a cooling problem in this case? Why are there no fans?

[@offgrid_power]

No, they should be fine.

[@omarutariq9501]

How much does this build cost the customer?

[@johnbull6909]

What is the advantage of a 48V system over a 12V system?

[@BLEACH500]

Higher voltage less amperage smaller cables less money

[@silviuflorescu6838]

Does your client knows that he can damage the cells at the first serios brake when they will touch the threaded rods between them? The aluminium case of each cell is connected to the negative port. Is he aware that he needs some heated pads between cells for freezing temperature? I also have a 16s 304Ah Eve cells on my camper, but I chosed a 200Ah JK smart bms with 2A equaliser. Daly is a garbage, not need to be stingy for a hundred bucks when you pay 3-4k on such a battery bank.

[@SkypowerwithKarl]

Agreed on all points

[@KoiAquaponics]

So it's 48v and about 300ah?

[@offgrid_power]

Yep!

[@AirmanJH]

Alibaba cells?

[@honumoorea873]

Insulate those rods with tubing....