I've just finished my first DIY project where I set up 12 Eco-Worthy server rack batteries with a Flexboss 18 inverter. Everything's been pretty smooth sailing so far. Right now, most of my house runs on the critical load circuit, except for the ACs, oven, and EV charger. I've had this system up and running for about three weeks, but I'm experiencing some issues with the batteries being out of sync. I've been charging them to 100% and draining them down to 10%, yet I'm noticing a 9-10% difference in state of charge (SoC) between them. I've read that adding bus bars might be a solution, and I'm curious:
* What's the best way to connect two server racks together using bus bars?
* If I decide to make my own bus bars, how do I determine the right size?
I'm looking for something that's reliable but not overly pricey. Any advice from those who have set up something similar would be greatly appreciated!
2 Answers
When connecting batteries in parallel with bus bars, make sure to draw positive from one end and negative from the opposite end. This way, it helps equalize the current across all batteries. Avoid connecting your inverter close to just one battery; spread the load evenly across the bars to prevent issues.
It sounds like you might have an issue with your wiring or perhaps some of the batteries themselves might not be functioning well. Check if a couple of batteries consistently fall out of sync. It could be a sign of bad cables or batteries. Also, take actual voltage readings with a multimeter because SoC can be misleading. In my experience, it's not uncommon for SOC to drift, but voltages should be pretty close—within 0.01V of each other. After a few cycles, you may find the SoC aligns again. I personally recommend using bus bars; they help maintain consistency and reduce the chance of wiring issues. By the way, make sure to use a proper torque wrench for tightening battery connections; specs should be provided in your installation data!
And don't forget that using a thermal imaging camera can help spot any wiring or connection issues you might have. It can really save you time in troubleshooting!