diy solar

diy solar

Hoping someone can fab some parts for me

John Frum

Tell me your problems
Joined
Nov 30, 2019
Messages
15,234
My eyesight is lousy and I've never been good with my hands.
So I could use some help and am willing to pay.

I have a couple of these busbars

These busbars are designed to work with these fuses

I want to also be able to use it for the return busbar.
Theres is more than way way to do this.

1. Fab a non conductive spacer to put under the busbar part #882-869-7
The spacer should be the same length and width as the orignial but ~5/8" thick

2. Fab a thicker busbar out of aluminum to replace the copper busbar.
The replacement should be the same length and width as the orignial but ~3/4" thick

3. Make dummy zcase fuses out of aluminum(I need some of those anyway)
Littelfuse makes a dummy fuse(they call it a shunt) part# 3298900._
Problem is I can only get them in lots of 480 with 14 week lead time.

The dummy should be ~1" square with an m10 size hole in the center
~5/8" thick

I've attached a pdf scan of the busbar.
If you are interested in fabbing these, lets talk first to finalize the design and agree on pricing.
 

Attachments

  • busbar_scan.pdf
    360.5 KB · Views: 25
Last edited:
Probably option#3 is the simplest and solves both problems.
From the mechanical drawing it seems a 25 mm square 16 mm thick with an 8.5 mm hole should do the trick.
 
The trick is the insulating bolt on that design. The bussman fuse uses a shoulder that insures the bolt does not contact the lower plate. I thought I could use just any buss bar but continuity checks prove me wrong. It was far more complex than I thought just looking at pictures.
 
The trick is the insulating bolt. The bussman fuse uses a shoulder that insures the bolt does not contact the lower plate. I thought I could use just any buss bar but continuity checks prove me wrong. It was far more complex than I thought just looking at pictures.
I have the insulating bolts.
 
Back
Top