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diy solar

Small battery post terminals

cbgeorge

New Member
Joined
Jan 12, 2024
Messages
19
Location
Greenwood Fla
I have noticed alot of 12 v 280 and even much higher AH batteries all have small tiny 1/4 inch bolt post connections, looks to me they would heat up when put in 48volt series under high amp draw. I just wonder if any one has had heat up issues with them since it such small connection point for high amp loads on them. I would think larger bolt with more surface area of contact would be better.
 
larger bolt with more surface area of contact would be better
Yes, but it don't bother for 200-300 amps.
M6 bolt can give way enough pressure and proper lug terminal diameter for M6 allow quite a large conducting area.

You can find M6, or even M5, bolt inside EV battery with 600-1500A of discharge and there is nothing wrong there.
 
A larger bolt would give a smaller surface area of connection.
The bolt only needs to be capable of securing the connection.

And we definitely don't recommend putting BMS controlled batteries in series.
 
A larger bolt would give a smaller surface area of connection.
The bolt only needs to be capable of securing the connection.

And we definitely don't recommend putting BMS controlled batteries in series.
I am new to the DIY solar, never knew that batteries in series you cant use a BMS, How would you manage batteries in series?
 
How would you manage batteries in series?
You avoid it.
never knew that batteries in series you cant use a BMS,
That's not what I said.
I said that it's not recommended to put BMS controlled batteries in series.
With LFP batteries, you always need a BMS.
But you should use the correct voltage batteries for your system.
 
I am new to the DIY solar, never knew that batteries in series you cant use a BMS, How would you manage batteries in series?

You can use them in series, but under certain conditions. First, under the assumption that you plan to charge the battery as one big battery, the individual batteries must have BMSes that support series battery-connections and the possible high voltages they may be subjected to in such conditions. Usually the battery listing will inform you of what they support.

Second, you need to deal with balancing. Just like the cells in a battery can become unbalanced - affecting performance and causing degradation -the batteries themselves can become unbalanced between each other. The BMSes handle inter-cell balancing, but batteries will not be aware of each other's state.

To help with battery balance, you'll generally want the batteries to have similar characteristics so that they operate somewhat synchronously (same discharge characteristics, voltages, etc.),. This can mean connecting multiple identical batteries purchased from the same seller at the same time, to increase the likelihood that the cells came from the same batch and use the same BMSes (or testing their characteristics to be sure). That's usually a context where series-connected batteries are depicted in battery sale listings.

On top of that, you will probably want to add an inter-battery balancer can help compensate for when they inevitably drift - but don't depend on it to compensate for batteries with very different characteristics. When hooking them up, the voltages should be the same too.

If you're not planning to charge the batteries as one big battery, you can also charge the individual batteries separately and hook them up together in series if you need a higher voltage bank. That can be a nice option for, for example, charging 12V batteries separately and connecting them together for higher voltage needed for a golf cart or something. Some people will still charge the whole bank at once, but avoid the inter-battery balancer, doing a manual rebalancing every 6-mo or so.

So check out other posts on the forum about this topic if you want some best practices.

With all the conditions above, if you're buying new, it's probably better to just purchase a single battery at your target voltage than cobbling together a bunch of lower-voltage batteries and adding a balancer (or multiple). Still, you can weigh your options, because sometimes multiple batteries + balancers is more economical than a single large battery if you have the space and time to do it right!
 

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