Colonel.lp
New Member
- Joined
- Jun 8, 2020
- Messages
- 135
Very good points.Interesting thread. A couple of observations though...
1) No one has mentioned the use of Lock Washers on the busbars - I use & recommend Serrated Washers as they are superior to split washers and keep an even balanced pressure.
2) Properly Binding & Securing your cell blocks is essential it is the correct method to use with the cells. Please Follow the cell Specification Data sheet information. Different brands & casing types have varying requirements.
3) I should point out that if people look at properly assembled commercial battery packs, quite often the busbars are welded to the cell pads and that those same cell packs are properly bound and blocked. Not only is that shown in some of Will's teardown but others as well. Not talking about the cheaper Chinese pre-builts (even some of them are starting doing it now) but the Higher end stuff.
A thought on Cable/busbars, that is 2 lugs (2 crimps) per, 2 possible points of issue, resistance etc.
Lithium Based Batteries are Not "Brute Force" like Lead, remember they ARE MILLIVOLT Sensitive and that goes for their sensitivity to Resistance !
REMEMBER why everyone is so picky about Matched Cells and Equal Resistances ! KISS Rules are always Best ! Time Tested & True. Do consider consequences and the potentials, sometimes a Good Solution may not actually be because of the side-effects.
4) Flexible Busbars are a good idea IF properly made from the correct materials, relative to application & environment. In a Marine Environment, Tinned Pure Copper mesh & lug-ends with Insulation is the way to go. See below. You can buy tinned mesh, sleeving as well and DIY them. Same with untinned, BUT you have to be confident that the connections/compression is "perfect". A Solid busbar has no weaknesses. It's easy to say and not hard to do but it is not easy to Make Properly, look closely at the commercially made ones & you'll see. (errant copper strands wreak havoc)
View attachment 61879
View attachment 61880
These are identical flexbars from Erico
REF: https://www.erico.com/category.asp?category=R2918
These & Others available at:
Hope it helps, Good Luck
Steve
Re the cable lugs, considering the reliability of the cold weld in a properly crimped good quality lug and cable in a dry environment, I really don't see it as a problem unless you are working with huge amps. Every system has its issues and weighing it up solid busbars had more potential issues than cable and lugs, despite the fact I'd prefer to use them. I will be monitoring the cells and if I see discrepancies I will be checking the cables, but at my normal draw of 5 to 10amps, 20amps solar charge in my camper, and occasional 80amp hookup charge, I'm not expecting problems.