Mike Jordan
Solar Enthusiast
- Joined
- Jun 15, 2020
- Messages
- 414
Yes, you are right. Welding wire is not solid eitherYes, but not welding wire...
Yes, you are right. Welding wire is not solid eitherYes, but not welding wire...
If you are going to use copper wire use some NoAlox or equivalent. I only use those for temporary connections. I prefer crimps. They are used all the time on main lugs with aluminum wire for service panels.this Aluminum-Lug with Aluminum or copper wire is another viable option for my use-case, I’ll price it out...
Thanks.If you are going to use copoer wire use some NoAlox or equivalent. I only use those for temporary connections. I prefer crimps. They are used all the time on main lugs with aluminum wire for service panels.
Ha, I sometimes respond to posts without reading the intervening responses.As I stated in an earlier post
As I learn more about aluminum galling on aluminum as well as galvanic corrosion, I’m back to considering this idea.Thanks.
As I stated in an earlier post, I priced it out and tinned lugs + 2/0AWH Welder’s wire is cheaper, so I’m dropping this idea and going with that...
Everyone keeps worrying about expansion and the effects of loading the terminals. This is basically only a concern because of the expansion of the cells, correct? Yes buss bars heat up and that is a consideration.
Has anyone considered a "non-standard" configuration (Narrow sides facing instead of broad sides)? Personally, I am configuring them in this way, using machined (flat) aluminum bus bars and epoxied zinc coated studs. I am still clamping them in a fixture, mainly because its a mobile application, but it will have some of the cycle increasing effects too I think.
I suppose the main issue is the form factor; you've got a skinny, 4.5ft long, battery if it's 4s, 9 ft long if it's 8s. Doesn't fit as many applications, I imagine. Still seems like a great idea for those who could fit it.I have thought about that configuration. But I do not think that I have ever seen it. So that made me think that there was a reason that I Wasn't thinking of. Have you started yet? Have pictures?
This is the configuration I am planning y to to use for 8S...I suppose the main issue is the form factor; you've got a skinny, 4.5ft long, battery if it's 4s, 9 ft long if it's 8s. Doesn't fit as many applications, I imagine. Still seems like a great idea for those who could fit it.
This may also be worth considering:
I'm not sure if this would be worse for longevity of connections, but instead of stretching the bus bars, you would essentially be rotating them about their lug connections as the cells expanded and contracted. 272Ah cells should have about a a 145mm distance between connections, diagonally.
The 9ft long configuration or the diagonal bus bar one?This is the configuration I am planning y to to use for 8S...
No, the diagonal busbar configuration composed of 2/0 welder’s wire on the standard 8S single-row cell positioning...The 9ft long configuration or the diagonal bus bar one?
Ah, gotcha'. I'm still considering aluminum bus bars, but my current go-to plan is #2 welder's wire for each of two 4S packs with a 120A BMS per pack, and then 2/0 welder's wire at the parallel connection between them. I assume for my purposes the ampacity is sufficient? I should be able to pull 240A but I doubt I'd ever be pulling more than 210A.No, the diagonal busbar configuration composed of 2/0 welder’s wire on the standard 8S single-row cell positioning...
No, Im still working through a few details in my head so not quite ready to put my money where my mouth is. Just charging the last 2 of 16 cells to test and this weekend will start building the fixture. Ill get some pictures up then.I have thought about that configuration. But I do not think that I have ever seen it. So that made me think that there was a reason that I Wasn't thinking of. Have you started yet? Have pictures?
Why would ac vs dc make a difference on wire design?If it was a solid wire, that would work OK. The verbiage in the HD page makes it sound like this is intended for AC, not DC, which would be a solid wire, not stranded.
Why would ac vs dc make a difference on wire design?
There is zero difference with stranded vs solid conductors ac vs dc unless you exceed 400Hz
But we understand there is NO current carrying solid wire used in 120v construction. You could not bend it, and the heating/cooling expansion/contraction breaks/cracks lugs, breakers, and terminalsI think he meant that it's solid core wire (or semi-rigid if it's a bigger size) meant to be put in house walls for 120 V for example (so AC), by opposition to fine stranded wire meant for battery cables for example (so DC).
Solid wire is generally small ga, (10 and under) but grounding conductors #6 and #4 are readily available, however, as you said, current carrying... #10 and smaller by code.But we understand there is NO current carrying solid wire used in 120v construction. You could not bend it, and the heating/cooling expansion/contraction breaks/cracks lugs, breakers, and terminals
The only solid wire in 120v construction is smaller 12/14g non-current carrying ground wires
No, he is discussing DC use case, and he stated DC must use solid conductors, and that is certainly incorrect.I think he meant that it's solid core wire (or semi-rigid if it's a bigger size) meant to be put in house walls for 120 V for example (so AC), by opposition to fine stranded wire meant for battery cables for example (so DC).