I used 1" x .185" copper bar stock for my bus bars, and 20 mm stainless studs. 20 mm seemed to be the sweet spot for me for the thickness of the bus bar and the BMS leads. I put some no-ox grease on the terminals before I bolted everything down. Then put heat tape over the terminals and connections. So far so good.
McMaster Carr has aluminum threaded rod on their website. They may have aluminum screws, too.
What is the problem with zinc?
I think they are worried about electrolysis. I have had lithium batteries in place for over a year now with mixed metals holding them together without any issue at all. This could be a problem 10 years from now but for now it is not. So I use zinc bolts
It is in the specs as a not to exceed number. I am using Nord lock washers.
From what I understand the early versions of these batteries had M4 terminal holes, but the latest ones are M6. My batch was ordered in early April and they’re M6. The latest spec sheet says M6 too. (Version E). Go with M6 terminals.
That's the rub isn't it. Its the conductivity between the aluminum terminal and the copper wire that is the most important.
My environment will be low humidity so hopefully the threads last 10 years. I have several fall backs if they don't. Retap the hole to the next size up or insert helicoils. I will also be happy if my cells last 10 years.
@Craig On this forum was selling some Chargery BMSs a while back. Check with him to see if he has any left. I personally use the Chargery BMS8T and have been very satisfied with it.
The BMS I ordered was a 120A. My needs are pretty simple for this project. It's a modern mini camper with all LED lights and a Dometic fridge that doesn't draw a lot of power. It's too small to consider running the air without shore power or generator.
