I don't have space restraints. I would connect each battery, fused, to a BusBar. That would give me the maximum 100 amperes from each battery and 400 amperes, fused, from the BusBar to the system. There are problems posible doing this, but less than using solid inter-battery connectors.
Where to get Bus Bars?
- Thread starter Neon
- Start date
I'm making my own bus bars for connecting components. See the link below.
If you're pressed for space, a copper bus bar can use less space than a 2/0 cable with lugs on each end.
Obtaining quality copper flat bar stock has been challenging. My first order (6' lengths of 1/8"x3/4" and 1/4"x3/4") took almost four weeks to arrive. The second order required a bit less. That was an online purchase from a metal vendor that I've used before and had good service from. I tried to source the same materials from a local vendor - for pickup - and they wanted at least three times the price and it wouldn't have been available for two weeks.
I'm using the Blue Sea PowerBar 1000. It's a monster of a common bus bar. It takes up a lot of real estate in my compartment. While I really like the PowerBar, I have some minor issues with it that I may clarify in a future thread that I'm thinking would be titled "Designing the Common Ultimate Bus Bar".
diysolarforum.com
If you're pressed for space, a copper bus bar can use less space than a 2/0 cable with lugs on each end.
Obtaining quality copper flat bar stock has been challenging. My first order (6' lengths of 1/8"x3/4" and 1/4"x3/4") took almost four weeks to arrive. The second order required a bit less. That was an online purchase from a metal vendor that I've used before and had good service from. I tried to source the same materials from a local vendor - for pickup - and they wanted at least three times the price and it wouldn't have been available for two weeks.
I'm using the Blue Sea PowerBar 1000. It's a monster of a common bus bar. It takes up a lot of real estate in my compartment. While I really like the PowerBar, I have some minor issues with it that I may clarify in a future thread that I'm thinking would be titled "Designing the Common Ultimate Bus Bar".
Custom Bus Bars From Copper Flat Bar
The first iteration of my system used all 2/0 cabling between the big components such as between the battery and the shunt and fuse. I'm in the process of rearranging my system to make way for an inverter/charger upgrade. In doing so, I decided to ditch the 2/0 cable where I could and use...
diysolarforum.com
Your buss bars came out nicely!I'm making my own bus bars for connecting components. See the link below.
If you're pressed for space, a copper bus bar can use less space than a 2/0 cable with lugs on each end.
Obtaining quality copper flat bar stock has been challenging. My first order (6' lengths of 1/8"x3/4" and 1/4"x3/4") took almost four weeks to arrive. The second order required a bit less. That was an online purchase from a metal vendor that I've used before and had good service from. I tried to source the same materials from a local vendor - for pickup - and they wanted at least three times the price and it wouldn't have been available for two weeks.
I'm using the Blue Sea PowerBar 1000. It's a monster of a common bus bar. It takes up a lot of real estate in my compartment. While I really like the PowerBar, I have some minor issues with it that I may clarify in a future thread that I'm thinking would be titled "Designing the Common Ultimate Bus Bar".
Custom Bus Bars From Copper Flat Bar
The first iteration of my system used all 2/0 cabling between the big components such as between the battery and the shunt and fuse. I'm in the process of rearranging my system to make way for an inverter/charger upgrade. In doing so, I decided to ditch the 2/0 cable where I could and use...
Bossrox
Solar tinkerer
I make my own using 1/4" thick, 1 1/2 wide aluminum bars. I'm not sure of the amp handling capacity but I'm feeding 100 amps thru them & they only get a little warmer than the ambient temp. A 10ft stick will run ya $15-20.
The Dish Doc
Photon Pharmer
Any opinions on this bus bar? I was looking a putting one of these on my small system. When asked about AMPs they state:
"There are serval factors that affects the amperage, such as environment temperature, placing it horizontally or vertically.
At temperature 25 degrees centigrade, placed horizontally, it's approximately 720A."
"There are serval factors that affects the amperage, such as environment temperature, placing it horizontally or vertically.
At temperature 25 degrees centigrade, placed horizontally, it's approximately 720A."
Last edited:
timselectric
If I can do it, you can do it.
- Joined
- Feb 5, 2022
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- 18,925
Looks nice
In one of the Q/A posts the vendor says it's good to 750 amps! That seems a bit optimistic but let's say you never exceed 400 amps. That's still a great deal. The mounting does suck a bit since the bottom bolts stick out.
I like that it has 5/16" studs instead of 3/8". The mounting studs may be a bit close to the edge, which would cause your lug to hang over the edge reducing the surface contact area. That observation may be a bit nit picky. My Blue Sea 1000 amp bus bar has the same problem. Below is a picture of what I'm talking about. Note how the big cable at the bottom hangs over the edge.
The Dish Doc
Photon Pharmer
Yes, I see what mean. Excellent observation! This will go on my three 100Ah AGM battery bank (puts on flame retardant suit)
. Should work for it but I'm planning a much larger system so that may become a concern. Thanks for pointing that out.
WindWizard
Solar Enthusiast
For my system I used 1/2" type L copper pipe. Just cut off the size you need and pound it flat with a press of hammer. Drill some holes in it. Sand it down. Plate it with a home aid nickel plating solution. Put shrink wrap on it and you are good to go. The voltage drops at 100 amp are around 2mv. The bus bars that I made outperform the ones I received when I purchased my batteries. I tried making some with heavy wire and lugs and they just did not perform well.
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timselectric
If I can do it, you can do it.
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Very nice
The Dish Doc
Photon Pharmer
Looks good
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