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How to make (or where to buy) battery interconnects | 9 comments (9 topical, editorial)
Re: battery interconnects (3.00 / 0) (#7)
by rossw on Tue Apr 8th, 2008 at 11:35:26 PM MST
(User Info) http://house.albury.net.au/

Not sure the size of your batteries... but I made my interconnects from 1/4" thick, inch or inch-and-a-half wide solid copper busbar I bought from a switchboard manufacturer as scrap.

Here is where the run turns around and heads back - the end one is a little wider and thicker, just to be sure!

As for crimped cables, I did mine with 35 sq mm welding "superflex"
Stripped end
Lug on
Crimped properly
Heatshrink and gland on
Finshed set

I always thought soldering was a better system too, but evidence is that a PROPER crimp acts more like a spot-weld, has a lower connection resistance and is actually superior to soldered connections.

The other problem with soldering multistranded cable is that where the solder ends tends to become a fracture/failure point and cables tinned and soldered thus, often fail prematurely (especially if there is vibration or movement over time).

Good crimps, especially if you seal them when completed, seem to last better and outperform soldered connections.

[ Parent ]



Re: battery interconnects (3.00 / 0) (#8)
by bob golding (photoman290 at yahoo dot com) on Wed Apr 9th, 2008 at 03:58:10 PM MST
(User Info)

yes i have heard that as well, which i why i suggested crimping them. only works if you use a proper crimping tool though. i use crimps on commercial equipment used in the entertainment industry, which is quite hard on leads and stuff. all that vibration and changes in temperature. what does woof think?

cheers
bob golding

[ Parent ]



Re: battery interconnects (3.00 / 0) (#9)
by wooferhound (tim((NoSpamAt))wooferhound.com) on Thu Apr 10th, 2008 at 08:54:17 AM MST
(User Info) http://wooferhound.com

I have also worked in making power distribution systems for the entertainment business, which also use high currant connectors. The connectors that I use handle 400 amps. In the beginning we crimped all the connections and vulcanized (melted rubber seal) the connector. In the end it was found that connections with Screw Terminals lasted longer and carry more currant without the need to be vulcanized. The wire size is 4/0 and would be quite difficult to solder.

In my RE systems I like to use soldered connections. But my max wire sizes now are 12 to 8 gauge and is fairly easy to solder with a blowtorch. My suggestion would be to solder the connections and use heatshrink tubing to insulate as much of the bare connection as possible. If soldering isn't an option then use connections with screw terminals, and if they aren't available then Crimp the connections. Use Screw Terminal strips for all other connections that are not soldered.
W o o f -={(

[ Parent ]



How to make (or where to buy) battery interconnects | 9 comments (9 topical, 0 editorial)

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