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Busbars / Terminal Blocks / LYNX Power In Dilemma

silverstone

Solar Enthusiast
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May 3, 2022
Messages
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Hi all :)

I'm facing a dilemma on how to connect all my batteries (build in progress) to the inverters, everything in parallel.

Every battery pack and inverter is fused (and also featuring a breaker) separately. In order to keep the current sharing as close as possible, I'll cut all cables to the same length, even though I'll have to do some "loops" in order to get to the closest battery.

They all join in a combiner box, which I'm building out of a Rittal AX 1360.000 cabinet (600mm x 600mm).
1675750452453.png

At first I was thinking of using some WAGO 285-1185 Terminal Blocks, as these are good up to 353A (Jumper only 306A), but in some fault scenarios (e.g. half battery packs disconnecting but still below each remaining battery fuse/MCB rating) that would result in an overcurrent situation which these terminal blocks (or their jumpers) were not designed for.

1675750277286.png

Then I had a look at the Victron Lynx Power In, which seems quite popular and used by many people.
Unfortunately it doesn't fit my use case, since I can only fit 2 Victron Lynx Power In horizontally (barely !):

1675750510280.png

So right now I'm considering using some simple copper busbars on some isolators and call it a day. I really liked the insulation and plug&play of the WAGO solution (no cable lug or ferrule required) and to some extent that of the Lynx Power In, but it's not flexible enough for my application (can only install 2 units horizontally but I need 8xbattery + 3xinverter "taps" plus maybe some more in the future, so minimum 3xLynx Power In, possibly 4xLynx Power In).

1675750885962.png


I'm considering 80x10 mm or 100x10 mm busbar, which will easily handle up to 1000A current, even with all the connection holes (with 3 inverters I can only get to 750A, but who knows, maybe i need to connect some more inverters in the future :ROFLMAO:). But looking online, the cheapest I could find was an Austrian retailer who sells them at 280 EUR (80x10x2000 mm) or 350 EUR (100x10x2000 mm), those were some bare copper busbars from Schrack. Heck I saw places at higher prices for a 1m only. I would need roughly 2x50cm (50cm for positive busbar, 50cm for negative busbar).

Do you have any recommendation or place where I can get it for cheaper ?

Thank you for your help :)
 

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As you can see I put coupling nuts on the Uni strut so I can have plexiglass covers on them when I’m done
 
That looks nice. I'm afraid the ground bars there won't work for me (I habe metric bolts, wrenches etc, not inch style bolts/nuts/wrenches). Maybe I can replace those bolts with m8 bolts or slighly enlarge the hole a bit... But where would you buy pre-bent plexiglass / polycarbonate covers that are the right size ? Or you bend them yourself?
 
The bolts fit a metric wrench 14mm I think and I make my own plexiglass covers you can heat with a heat gun and make bends pretty easy just take your time don’t burn or scorch it
 
You mention 48 volts but your diagram shows 12 volt batteries, which is reality?
 
You mention 48 volts but your diagram shows 12 volt batteries, which is reality?
It's 48V, I just used a simple symbol to show a battery ;), I didn't mean it as a "4s". It's 16s1p configuration for each pack ;), 48V (so up to 60 VDC fully charged).

Inverter is Deye SUN-12K-SG04LP3, so 12kW and up to the 250A of current I indicated in the diagram.
 
Looks quite good, but I'd say quite expensive too :(. 2 of these (1 for each polarity), plus like 2x65 EUR shipping&duties to europe ... That's over 500 EUR almost :(
Don’t know about your rules, but if you can make your own, you can buy copper bars on eBay.
 
It's 48V, I just used a simple symbol to show a battery ;), I didn't mean it as a "4s". It's 16s1p configuration for each pack ;), 48V (so up to 60 VDC fully charged).

Inverter is Deye SUN-12K-SG04LP3, so 12kW and up to the 250A of current I indicated in the diagram.
12000 ac watts / .85 conversion efficiency / 48 volts low cutoff = 294.117647059 inverter amps
294.117647059 inverter amps / .8 fuse headroom = 367.647058824 fuse amps
367.647058824 fuse amps * 3 inverters = 1,102.941176471 busbar amps

Just for reference the lynx distributor busbars are 8mm * 30mm = 240mm2
 
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