Installing Batteries into DIY Powerwall Cabinet, Chevy Volt Gen 2

In this video we actually install the batteries into the wall-hung cabinet. Our DIY Powerwall is coming together!
These batteries are pretty heavy, so I even added some extra bracing since the cabinet build video.
Before installing the batteries I tap all the terminals with long wires so I have less wiring to do inside the cabinet.
This system is part of the larger off-grid solar system we are building. In previous videos I built the solar panel mounts.
Thanks for watching.
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[@johnhudson8197]

David, to say that I'm impressed with your project is an understatement! I built my own dual-axis solar tracking system (monocrystalline 250w/8a panels). Set it up on a concrete pad in my 1/2 acre back yard. Ran #2 cable to the MPPT charger, solar battery bank, pure sine wave inverter, transfer switch, with all the panels and gauges. At 70 years of age I did this all myself (now 72!). I cringed watching you pick up those Volt battery packs - DANG! Too much for me - I set mine up on a bench system I built myself so I wouldn't have to lift them as you did! Electricity isn't rocket science, but I did take time to download the Natl. Electric Code to ensure my wire sizes were okay - might want to spend a few minutes there. I am fascinated by your use of a Chevy Volt battery system... I'm trying to find your video explaining that part of your system. You're a lot of fun to watch, my young friend - keep up the good work and please be safe. John

[@stevensaxon8888]

Would like to see pictures of the solar track system. Any plans to sell?

[@10mbard0]

Those long threaded rods that you mention at the end are needed to keep the pouch cells compressed. Reduces mechanical stress when pressure builds during charging

[@BoDiesel]

David Poz is a beast! Muscling all this stuff alone all the time! Haha

[@DavidPozEnergy]

Thanks. I've got to stop doing this to myself or I will break soon.

[@Dutch_off_grid_homesteading]

heya yes yes 1 more very nice vlog love the set hope by now every thing is still woorking well

[@InlineSkater44]

Watched Most of your videos on the Chevy Volt batteries Power Wall. When I watch videos on How to DIY's, on anything I watch from Electrical to Motor rebuild, I usually think and wish that the guys making the videos would include what to use (Standard or Metric) and what to use, (Wire Gauge size) instead of just doing it. Even though it is painful to watch, (Takes up So much video time) Thank You for doing so.

[@DavidPozEnergy]

Thanks Joseph, It's always a balancing act between putting out enough information without being a dry video. I'm glad you like them.

[@g0dfath3r71]

I am enjoying this project. I am very curious to see your inverter setup. That part is the only thing currently stopping me from moving forward. Thank you for sharing!

[@DavidPozEnergy]

Hi Scott, Thanks for watching. Eventually I hope to buy a pair of Magnum inverters, but I've got a while to save enough money for that.

[@southernohiosolarhomestead8477]

Nice score on your batteries, looking great 👍

[@mikemiller9119]

That was an impressive lift.

[@Housemouse7777]

I'm learning alot. Which is good Cruz I'm doing basically the same thing Sept with a 24v system

[@kestreltom]

Hello David. You seem like a nice guy, and I don't really want to rain on your parade, but you are running a risk of burning down your shop there. Here's why; 1.) If you do not use a BMS designed for those cells, then it is only a matter of time before the cells get out of balance, and they will - once that happens the battery can self ignite during charging 2.) Each and every one of those individual cells can easily deliver over 400 amps, thus the un-fused #10 lead wires to the tabs on top of the sub-groups are woefully undersized. The 30 amp auto fuses you are using some distance from the cells are inadequate because they must be capable of containing and quenching a 400 amp arc (you demonstrated this). If the auto fuses are bundled too closely together then when you blow a fuse, that arc flash will attach itself to, and bridge or short other leads and could start a fire (or explosion) almost instantly 3.) Since you are not using the excellent liquid cooling capability of those packs, you are also running a risk of thermal runaway since those packs were not designed to be air-cooled. I really want your off grid system to be successful, but it is more important to be safe first. As an investment in the future and a good way to start thinking about safety, read the National Electric Code - any version written in the last 8 years will do since (I am guessing) you are not pulling permits. There are sections on wire sizing, fusing, even solar installations. Boring... I know, but it might save your life... or of those you love. Good luck!!

[@mdrmoose]

Journeyman wireman here and your definitely right. He had good intentions but this was done all wrong. Only plus is he installed them in a enclosure so at least when they explode it may save him.

[@caserio323]

@@mdrmoose no explode jet! i guess is working fine

[@glenngoodale1709]

your doing a fine job

[@glenngoodale1709]

As always, awesome video ....

[@jontscott]

I like your thought on making all the wires the same length. Sounds good in theory to me. It seem one group still ends up with longer total wire runs since you have the links between the small groups of cells? Nice job lifting those modules up there. Having an older Chevy Volt pack myself I know what a pain they are to move.

[@DavidPozEnergy]

You are absolutely right, that the broken up cell group has the wires in between. I plan to cut down the main +/- wires for that one battery as much as I can to try and equal get it's total wire length closer to the 14 feet on the other 7 batteries. Thanks for watching.

[@ardo111]

Nice new intro David!!! Just finished watching your entire crawl space and garage solar water series’! Have you done an AMA? You should!

[@DavidPozEnergy]

Thanks for watching the series. What does AMA stand for?

[@ardo111]

DavidPoz “Ask Me Anything”! KZbin live would be a good way to do it! Some also use Reddit AMA to do it in written form. Best results when planned in advance and lots of people can tune in!

[@Housemouse7777]

Magnum is supposedly made in the USA. And is very programmable it why I chose it

[@DavidPozEnergy]

I've heard good things about Magnum.

[@DavidSmith-dm8ew]

is the awg of the wire going to be enough...I would have used 4awg or larger if your going to pull 20+ amps per pack. I use 10awg from the charge controller and 1 awg to the inverter.

[@DavidPozEnergy]

I'm going to fuse each battery at 30 amps, which I think is the max rating of 10 gauge wire. However, if I'm wrong, and 10 gauge wire needs to be fused less then I will certainly do so.

[@dwfdwf5371]

I wondered the same thing as DC voltage requires multi strand heavy wire I would have gone with battery cables but maybe it will be good, time will tell 4awg is rated 50 amps or less

[@adrielrowley]

Bet you felt that the next day... A bit of a feat walking that up the ladder.

[@leobuildsit]

David, the batteries were designed to use liquid cooling for the load from the car. What performance degradation are you expecting from the batteries using passive cooling vs an active cooling system?

[@DavidPozEnergy]

I'm going to monitor the temperatures. If there is a problem I'll address it then. I don't expect a problem because my garage is heated and cooled. These batteries won't be exposed to temperature extremes like they were in a car.

[@billschlembach8055]

I fear the charging and load during discharge is going to be the thermal concerns, not ambient temperature of your garage. My Volt runs coolant pump during charging from garage temps of 60 degree F due to cell temperatures during the last hour top off of cells... GM only allows the cells to reach 80% charge and no higher. How will you handle charging in the same manner?

[@IBkeeping]

Just a thought on the cooling, chevy designed the cooling case for the batteries, however the batteries themselves are a standard flat polymer type lithium ion battery I think. They should be ok. Was also thinking that you may be able to mimic the cooling system and have it on a pump with a thermostat.

[@lyles637]

Why did you put the heaviest battery on top? Interesting project David!

[@DavidPozEnergy]

No particular reason. Thanks for watching.

[@dwfdwf5371]

Don't mind me but a ladder to put in batteries, just wondering why so high, and above the inverter, I guess they don't leak like lead acid. But boy a lot of grunting to get them up there, you have a large and very nice garage.

[@DavidPozEnergy]

I wanted to try and use the vertical space in the garage. I don't need to get to the batteries on a regular basis for watering (like lead acid). The low space is a premium for things that roll (snow-blower, generator, air compressor, etc.)

[@rogerkerkmann]

DavidPoz i thought you were in a flood zone! :-)

[@DavidPozEnergy]

Nope, I checked FEMA's map before buying this property. Not a flood zone.

[@itsjustmetomc4848]

How's your hernia doing? LOL That last battery was a bit heavy my friend. Nice video!

[@DavidPozEnergy]

LOL. Thanks for watching.

[@maxleader8745]

I see you're not using the cooling system from the Chevy Volt. Are you using the BMS battery management system that came with the vault volt volt so I guess we want to make this thing for format as well as we can but do we need this additional technology?

[@DavidPozEnergy]

The BMS that came in the battery is designed to work with the car's computer, and to operate at the original 360 volts. I'm using this as 48v, and I don't know how to write a programming hack to use the original BMS. It would be very cool if someone out there figured it out.

[@teamkhattak8545]

I realy like this video

[@caserio323]

David i got a ? how many cell in each block they are? i looking to buy the same battery. just do not know how many for a 48v config, led me know please. thank you, by the way Grate Videos david

[@DavidPozEnergy]

This is a Gen2 battery (2016 and newer). The battery is broken into modules of 16s and 12s (12 cells in series). I re-wired the 16s modules to 12s and I'm running everything in a 12s configuration. However, I want to re-wire everything to a 14s. 14s is the ideal configuration for 48v. If you are buying a whole car's battery then you will have the option from the beginning. Connect with me on Facebook if you want to talk specifics about your build. facebook.com/DavidPozEnergy/

[@Solar_Tech_Liam]

Are you planning on this being a high voltage pack? Because if not, and you are going for 48V, then 10AWG is WOEFULLY insufficient for any kind of large power levels, NEC max ampacity in free air is 55A which is only about 2.6kW at 48V, if you use the code required rating of 30A, that drops further to under 1.5kW. Am I missing something obvious?

[@DavidPozEnergy]

Hi Liam, I am using this as a 48 volt system. You are right that those wires are going to max at 30 amps, which is the size fuse I bought for them. (I show the fuses here: kzbin.info/www/bejne/paWWepupist5iZo at 3:37) The part that is not obvious in this video is that I'm going to hook up the system in parallel, which means that I can pull 30 amps from each battery. There are 8 batteries on the wall making up the battery bank. 8x30=240 amps x48v = 11.5kw. This should become clear in my next video, but please let me know if I don't explain it well. Thanks, David

[@travelrevolt992]

I haven't done the math, but distance is a huge factor. Short distances do not require big wire.

[@Solar_Tech_Liam]

That does make much more sense. Now that I think about it, it's very similar to some of the LG home-storage batteries (each brick connects to a bus bar and then to a master breaker). I did hear you mention a bus bar in this video so I'm guessing that's going to be your combining point. Very nice work so far, would like to have a shop that large :-) currently have everything crammed into an 8x20ft space. Are you going to have a Midnite breaker on the cabinet to disconnect the battery from the inverter? Excuse all the questions (which you will no doubt cover in the next video) I do this for a living so I like to see how other people approach the same problem.

[@DavidPozEnergy]

Hi Liam, Thanks for the comment. I'm glad I have a pro watching to check my work. Yes, I plan to buy midnite solar breakers from Alt-E. Eventually I plan to purchase a Magnum inverter (but I have to save lots of $$$). I read Magnum's installation manual and they said a 175 amp DC breaker for each inverter. I already have a midnite combiner box with breakers out at the panels. Do you have any suggestions for the breakers?

[@Naushadkhan78623]

Make a complete video about the ways to charge these battery

[@DavidPozEnergy]

I charge them with solar: kzbin.info/www/bejne/bWOVeIGNoaqBZ8k

[@bgabreal1212]

I think you are going to buy a Portable Hand Winch Lifter ! it will help you more

[@seanwyntwrs7461]

Okay so the one thing you have to remember about batteries in about electricity. The more amperage you plan on drawing from those batteries the thicker the wire needs to be to carry that current 10-gauge wires okay but it's not ideal for what you want to do

[@donaldsmith3048]

May I ask why you put the heaviest battery on top, the hardest place to lift something to?

[@DavidPozEnergy]

Hi Donald Smith, Sure. I have some diagonal bracing in the middle between the two shelves. Sorry I didn't show that well in the video. Thanks for watching.

[@donaldsmith3048]

@@DavidPozEnergy I just thought it would be easier to lift the lighter one to the top than the heavy one.

[@scottmccluremcclure3916]

Please change terminal ends to solder on copper alloy

[@DavidPozEnergy]

Hi Scott, The ring terminals I'm using are tin-plated copper, rated up to 45 amps.

[@JoseGarcia-px9xj]

what should be the maximum difference between capacities for cells to connect in parallel in a pack(2900 with 1700 should be ok)

[@DavidPozEnergy]

I don't know. Hopefully someone else can help you out.

[@BecomingOffgrid]

Where did you get the cabinet? That thing is an awesome beast @DavidPoz

[@DavidPozEnergy]

Thanks. I built it.

[@joanandestin4201]

Hi david, I really like you diy experiments.I wish to build one as well but I do not know where I can buy the chevy batteries. Could you send me the name or number of the seller?

[@DavidPozEnergy]

Actually, the seller told me not to mention his name. I bought the batteries from a salvage yard. Sometimes people call these places Junkyards, or Auto Salvage, or Used Auto Parts, or Auto Recyclers. Try going to Google Maps, typing in "Auto Recyclers near me" and you will see the map populate with them. Then I just started calling asking if they had any Chevy Volts, Nissan Leafs, Teslas, or any other electric vehicle batteries. It took several hours of calling around before eventually finding one. Another option is Ebay.

[@winnipegnick]

Recommendation #1: Have a strong friend there with you next time you pick up something that heavy 🏋🏿‍♂️😆

[@DavidPozEnergy]

I asked Eleanor for help, but she just sat in the stroller.

[@59seank]

Eleanor is wise beyond her years. My back is having sympathy pains for your back.

[@kungfooxmas]

Nice job! Any updates on how it's all working? I have just finished getting 8 modules ready for installation in my trailer. Gen 1, 48v system with victron components.

[@DavidPozEnergy]

The batteries are amazing! I'm still not 100% finished with my solar mount, and solar wiring so I have not been pushing the limits yet. But I have been impressed with the capacity of the batteries. I do wish I had re-wired them to 14s, but so far the lower voltage has not killed the inverter. If I ever have to remove the batteries for any reason I'll re-wire them at that time.

[@rogeriodasilvaoliveira3939]

Good afternoon, my friend, beautiful project, I'm following your channel and I learned a lot. And I already have my project set up generating 6kwh per day, this one with electric car batteries can store how many kwh per day? Thank you

[@DavidPozEnergy]

This Chevy Volt battery is rated at 18 Kwh capacity.

[@daltonbryer3171]

Since these batteries are water cooled try water cooling each battery with its own PC water cooling system.

[@DavidPozEnergy]

Excellent point. I kept the liquid cooling system intact on the batteries for exactly that purpose. I figured if they showed any signs of getting hot I could easily add a cooling pump/radiator. Luckily, they have not shown any signs of getting hot, even when being fully charged with all my solar panels.

[@dannymitchum5]

it on showed it to be 44 volts. what should it be?

[@DavidPozEnergy]

44 volts is a good voltage reading for the 12 cells in series. Thanks for watching.

[@johnnyrizzo8057]

Do these batteries need to be cooled by air or water when drawing amperage from them? Probably would last longer with less heat

[@DavidPozEnergy]

Hi Johnny, They were built with water jackets between every pair of cells. This allowed the car to pump coolant through them to offer both cooling, and heating. Pretty neat way they (Chevy engineers) did that. When I removed,mounted them on the wall I kept the water jackets intact. If I notice heat build-up then I will connect the hoses and install a radiator. However, I very much doubt I will need to heat or cool them. I'm keeping them inside a conditioned building, not outside in a car. Also, I won't be pushing/drawing high amperage such as you might expect in a car. If things change I will post a new video about it.

[@mrparker351]

why did u put your powerwall up so high?

[@DavidPozEnergy]

Hi Chris, I located the powerwall high on the wall for a couple of reasons, but none are a deal-breaker and it could have been located lower. My basic thinking was this: I wanted it out of the way of car doors opening up, or possibly my snow-blower or something hitting it. Also, I wanted it higher than my outlets so as not to block them. I also figured I didn't need easy access to the batteries themselves, just the bus-bars and inverter. Both of them are in the lower section of the box at perfect working height.

[@shepherdspathrev]

What kilowatt hour is each 44 volt battery?

[@DavidPozEnergy]

2.3 kwh per 44v battery. This is the Gen2, but if you buy the Gen1 they are 2.0kwh per battery. You can buy some here, with 5% off using my code DAVIDPOZ: batteryhookup.com/products/7kwh-chevy-volt-battery-42s-3x-12s-and-1x-6s and batteryhookup.com/products/4kwh-chevy-volt-battery-24s-2x-12s-modules

[@InlineSkater44]

7:17 MAKE THE BABY DO IT. make her make her keep...

[@mvreneetwhatleywhatley837]

What ever happened to your Chevy volt battery wall

[@pauldonovan5878]

I think the wire gauge is to small , should be the same as the Volt!?!

[@arakansander6395]

what kind of battery is it? how can i buy it i live in thailand

[@DavidPozEnergy]

It is out of a car, Cevy Volt.

[@mikepruett1745]

how did u get these batteries

[@DavidPozEnergy]

I did a google search for "auto recyclers near me" Then proceeded to call them, one at a time, in an ever-growing radius. After about 100 calls I found a Chevy Volt and bought the battery out of it. Thanks for watching.

[@mikepruett1745]

@@DavidPozEnergy how much then was it id like to see also

[@DavidPozEnergy]

$2033

[@mikepruett1745]

@@DavidPozEnergy wow typical used parts "junkyards: lol

[@Clark-Mills]

Maybe easier to put the BIG battery at the bottom and the 2 smaller ones at the top? I busted a foo-foo valve just watching you put the large battery up top... :)

[@DavidPozEnergy]

LOL

[@InlineSkater44]

10:49 I would think it would be Safer to put the wires in front and away from wood, if ever a short, would burn the wires and catch the wood on fire. Just imagine, a wall of batteries coming down, on fire, to the floor.... CAN YOU SAY OUCH?!?!?!??!?!

[@leobuildsit]

David, I too have a battery bank at my house for solar storage. I used 12v 35-40 AH mobility scooter batteries, my current system stores about 5 KW of usable electricity with a 1 KW and a 400W inverters. One for workshop lighting and the other for emergency power for lighting and fridge use, as I'm a Florida native. Though my batteries are sealed AGM batteries and were free, I'm thinking of upgrading to these: www.batteriesplus.com/productdetails/sligc110 which when run in series to make 12v pairs, will store 2.5 Kw of electricity for about $200 ($100 per 6v battery).

[@DavidPozEnergy]

That's great. It's good to have a form of backup, especially you in hurricane territory.

[@georgejenkins8063]

You need something like welders lead doubled up for what you are attempting you are overthinking length/voltage loss and underthinking bulk. Careful my friend.

[@georgejenkins8063]

Yeah... Be carful gold is the no. 1 conductor as I.m sure sure know. My dad had his wedding ring and watch melted from his arm when I was 14. Scarry Scary stuff.

[@pauldonovan5878]

Any time and every time you are working with D/C Wiring, the shorter, the better! Read about Tesla Vs. Edison! A/C vs. D/C?!?

[@edgdeal76]

Forget the battery. Who the hell makes that ladder?

[@DavidPozEnergy]

LOL, I think that is Werner.

[@InlineSkater44]

8:19 LAUGH OUT LOUD....

[@BlakDrgn]

If your house burns down and your insurance finds that in your shop, burnt or not, they're going to tell you to take a hike because it isnt UL rated or somecrap. Found this out about a wood stove we had that wasnt rated. Thing was built like a bomb shelter, but no rating? yeah, insurance would find it in the rubble, and tell you goodbye. Yer gambling here dude.

[@simonac688.]

Hi David arenth you concern for fire hazards...i would what about your insurance Co. shoudnt you get an experts advice before using this potentially fire hazard..power pack .(just saying) just a bit concernd my friend...good luck...:)

[@DavidPozEnergy]

Hi Beez, I don't consider this any more dangerous than what we (general population as a whole) surround ourselves with every day. Thanks for watching.

[@Wingman77tws]

You used wayyy to much wire,and there is no need for the "equal lengths" thing you were talking about.

[@joelarrabee4018]

F