Connecting Wires To Battery Board: Technique?

[PeteCress]

The boards in question have a little hole in them.

I've been tinning the wire, bending it to ninety degrees, inserting it in the hole, and then applying the soldering iron hoping I don't cook the board.

One just came loose on me - probably a bad joint to begin with, but in trying to reattach it, I think I'm flirting with a cooked board.

Is there a better way to so this?

Maybe some sort of mechanical device that goes into the hole, screws tight, and presents it's own place to attach the wire?

 

[Rassy]

Pete, When I got my first batteries with BMS three years ago, one of the BMS boards was bad. The replacements, got one from Anna the original vendor, and a spare from Ping, didn't have the battery wires attached. Being very poor at soldering and not having good tools, I just added a small stud connector on the end of a wire and then bolted it to the board through the "hole" that was already on the board using a small bolt and nut and washer. Never had any issues with either of the BMS boards.

Another Pete

Edit: And both of the modified BMS's were in service the whole time, because the other original BMS had a "hot" spot so it was put on the shelf early on. Those batteries both started delivering only about 1/2 their AH's last summer, and I have since given them away.

 

[PeteCress]

... I just added a small stud connector on the end of a wire and then bolted it to the board through the "hole" that was already on the board...

I used #40-something-or-other brass screws. Solder seemed to adhere better to the brass.

Needed steel to cut threads in the holes though - the brass would shear under the stress.

Eventually the wires will fatigue and break aft of the screws. Then the question becomes "How many removals/insertions before the hole wears to where the contact is insufficient?". At that point, I guess it escalates to washers and nuts.

But for now, it's rock-solid albeit butt-fugly:
That's mastic tape on the sides: easier on the hands during insertion/removal.