How to connect wire to battery busbar

Get all your technical information about electric bikes here.
Post Reply
n1866878   100 mW

100 mW
Posts: 47
Joined: Jul 09 2018 2:58pm

How to connect wire to battery busbar

Post by n1866878 » Aug 13 2018 3:28pm

Hi,

We're in the process of assembling around 195 18650 cells in order to power our ME0909 PMDC motor at 48V. It's rated for 100A continious and 300A for 30 seconds.

Our cells will be joined together by massive bus bars and there will be two main bus bars - each being able to carry 150A, giving us a total of that 300A. I'm using 2/0 AWG wire. My question is -

Q1 :What sort of connector/lug/adaptor to I need to put onto the bus bar in order to join the wire to it?
Q2: How exactly do I join it - do I just use a ton of solder?
Q3: Since there are two bus bars - each carrying 150A each - that means two wires. Eventually, those two will have to combine together. Do you know of any "Y splitter"'s for 2/0 gauge wires that I can get? What's the common way of joining together two wires?

All 2/0 AWG.

Jon NCal   1 kW

1 kW
Posts: 369
Joined: Jun 15 2015 3:59pm
Location: Mendocino, California

Re: How to connect wire to battery busbar

Post by Jon NCal » Aug 13 2018 9:05pm

I would suggest Burndy compression lugs.

n1866878   100 mW

100 mW
Posts: 47
Joined: Jul 09 2018 2:58pm

Re: How to connect wire to battery busbar

Post by n1866878 » Aug 13 2018 9:34pm

Jon NCal wrote:
Aug 13 2018 9:05pm
I would suggest Burndy compression lugs.
Oh. Are those just standard lugs? As in, can I just crimp the wire to one end and then drill a hole on the bus bar to mount the flat side of the lug?

Jon NCal   1 kW

1 kW
Posts: 369
Joined: Jun 15 2015 3:59pm
Location: Mendocino, California

Re: How to connect wire to battery busbar

Post by Jon NCal » Aug 13 2018 10:38pm

n1866878 wrote:
Aug 13 2018 9:34pm
Jon NCal wrote:
Aug 13 2018 9:05pm
I would suggest Burndy compression lugs.
Oh. Are those just standard lugs? As in, can I just crimp the wire to one end and then drill a hole on the bus bar to mount the flat side of the lug?
Yes, but the lug has to fit your cable gauge exactly and you have to use a crimper with jaws made for that type of lug. Bus bar often has double row of holes for 2 hole lug.

User avatar
Hwy89   1 kW

1 kW
Posts: 442
Joined: Mar 03 2013 9:52pm
Location: Northern Arizona

Re: How to connect wire to battery busbar

Post by Hwy89 » Aug 14 2018 12:09am

httphttps://www.homedepot.com/l
2-Port/1-Sided UV Insulated Standard Wire Connector

n1866878   100 mW

100 mW
Posts: 47
Joined: Jul 09 2018 2:58pm

Re: How to connect wire to battery busbar

Post by n1866878 » Aug 14 2018 3:40pm

Jon NCal wrote:
Aug 13 2018 10:38pm
n1866878 wrote:
Aug 13 2018 9:34pm
Jon NCal wrote:
Aug 13 2018 9:05pm
I would suggest Burndy compression lugs.
Oh. Are those just standard lugs? As in, can I just crimp the wire to one end and then drill a hole on the bus bar to mount the flat side of the lug?
Yes, but the lug has to fit your cable gauge exactly and you have to use a crimper with jaws made for that type of lug. Bus bar often has double row of holes for 2 hole lug.
Ah. I'm using a 70mm2 lug for my 2/0 AWG wire which is 68mm2. This one to be precise
https://www.ebay.co.uk/itm/Copper-Tube- ... 1926498818

I'll just crimp the 2/0 AWG wire on one end and screw in the other end onto the bus bar. We'll have two bus bars, each carrying 150A at max. So I'll eventually need to combine those two seperate 2/0AWG wires together - how do I do that? Are there any Y splitter type things?

dustNbone   10 kW

10 kW
Posts: 950
Joined: Mar 13 2016 9:59pm
Location: Vancouver, BC

Re: How to connect wire to battery busbar

Post by dustNbone » Aug 14 2018 8:53pm

You can just use a split bolt to connect the 2 (or more) wire ends together.

Something like this

https://www.gescan.com/products/fittings/t-b-6h-26322

Wrap it up good with some proper splice tape.

Post Reply