Busbars (again)

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So the amount of equipment is slowly outgrowing what can be done by connecting cables together at various points, and I now need at least a busbar for the negative side (so the BMV shunt can sit between that and the battery bank), and probably also for the other end to make it neat. Of course I could use these nice Blue Sea thingies, and I could get away with a 150A unit for now, but I don't like the thin studs (quarter inch, aka about M6), and I'd like to future proof it a bit. The next one up costs R500+ though... which seems excessive especially if you want two. The electrical contracting places wants to sell it to me by the meter (aka thousands of bucks) and I just know AC/DC isn't going to have it in stock and will have to order it, though that is probably okay.

So before I do anything else, what do you guys do for busbars? I really just need a short length capacble of 200A (ish) where I can join 4 or 5 cables together.

Also, how do you mount them and protect them? I'm thinking a poly carbonate case (the kind that's flame retardant) with a clear front so you can see the stuff inside. Can probably put the BMV shunt in the same case. Pictures welcome.

[PaulF007]

Hi @plonkster 

Do you have specks on the busbar , size thickness extr.

Maybe it can be manufactured?

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5 minutes ago, PaulF007 said:

Hi @plonkster 

Do you have specks on the busbar , size thickness extr.

Maybe it can be manufactured?

Well, thumb rule (for AC, though I doubt that matters) says 1.2 amp per square millimeter cross section. Flatter is better for AC (due to skin effect), so what I'm likely looking for is 38mmx5mm or something like that. But there has got to be some standard stuff you can buy somewhere...

[Mark]

If anyone finds a length I am also looking for about 300mm.  1 pos and 1 neg bar.  I'll drill and thread them myself so some solid (read overkill) copper bar...

Thanks Mark

[Riaanh]

Any of your local Electrical Wholesale outlets should be able to assist you.

I went for the "blank" option and got from Zetty's here closeby, If memory serves me well, like under R30/meter. Just drilled and tapped myself to my needs/specs.

I found the pre-drilled ones were like 2 - 3 Times the price.

[Chris-R]

Hi Plonkster,

Attached photo of what I did. If you think it could work ( 40mmx 5mm ) let me know what size you need and I might just be able to help you. You can fit them with normal isolators.

[Don]

Very neat job @Chris-R. 

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56 minutes ago, Chris-R said:

Attached photo of what I did.

Precisely what I have in mind. If I don't come right, I'll be in contact. Surely someone somewhere has some copper bars. Looks like ACDC might have some, they may just have to order them.

[Chris-R]

1 minute ago, plonkster said:

Precisely what I have in mind. If I don't come right, I'll be in contact. Surely someone somewhere has some copper bars. Looks like ACDC might have some, they may just have to order them.

I've had to buy 4m of the stuff, gave half away and still have some lying around. I see your location is "gone" or else I might be able to organise something for you

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2 minutes ago, Chris-R said:

I see your location is "gone"

LOL. Remnant of me almost walking away (at least for a while) recently, with the whole blow-up. I'm in Somerset West.

[Chris-R]

44 minutes ago, plonkster said:

LOL. Remnant of me almost walking away (at least for a while) recently, with the whole blow-up. I'm in Somerset West.

Let me know what your requirements are and whether that size (40x5mm copper) will do./ My brother is in the Strand, and I think we will be able to organise.

[Energy-Jason]

Heya all. Hope this helps.

We have these available if needed. Bluesea - Great Company.

[Energy-Jason]

Prices might be a bit out on the old store: https://powerforum-store.co.za/collections/accessories

Hope this is useful.

Sincerely

Jay

[Energy-Jason]

https://powerforum-store.co.za/collections/accessories/products/powerbar-4x-3-8-16-stud-terminal-600a

600A is a monster. haha

[Mark]

Let me know what your requirements are and whether that size (40x5mm copper) will do./ My brother is in the Strand, and I think we will be able to organise.

Thats the stuff Chris. I could take 2x 150mm or even 4x 100mm.

Many Thanks

Sent from my SM-G800F using Tapatalk

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7 hours ago, Energy said:

Heya all. Hope this helps.

We have these available if needed. Bluesea - Great Company.

The trouble is that the one I want is R500, and I need two... so perhaps it isn't that much money in the big scheme of things, but for the same price I bought almost 30 meters worth of aluminium... :-)

[superdiy]

Worst case, get some class 2 copper pipe from your local plumbing supplier and flatten it.

[___]

I found some bars! I had to drive to three different wholesalers, but the third one (Cronlec) had them, 300mm long, 105mm high (approximately) on isolators, with M8 holes, bolts and washers. Technically it's an earth bar. It's probably good for 600A or so. Just under R200 a piece. Yes, you can get it cheaper, but then you have to drive to some faraway place in a faraway industrial area. Now the next challenge... something to mount them in.

[DownTime]

 

13 minutes ago, plonkster said:

Now the next challenge... something to mount them in.

 UT7 slide lid box with the wooden backing on the inside AC/DC should have them as well as Voltex.  Remove the two srews holding the wood onto the box, mount drum busbar insulators onto the wood, put it back and then mount the busbar on the insulator

[Mark]

36 minutes ago, plonkster said:

I found some bars! I had to drive to three different wholesalers, but the third one (Cronlec) had them, 300mm long, 105mm high (approximately) on isolators, with M8 holes, bolts and washers. Technically it's an earth bar. It's probably good for 600A or so. Just under R200 a piece. Yes, you can get it cheaper, but then you have to drive to some faraway place in a faraway industrial area. Now the next challenge... something to mount them in.

Is that 105mm high or 10.5mm high...

Send a pic please

M

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2 minutes ago, Mark said:

Is that 105mm high or 10.5mm high...

105mm. I didn't measure it (yet). What I did was hold it up to my car key... okay, about as high as the key is long. Then in the office I could not find a ruler (friggin computer age!)... so I find that the car key is about half of an A4 page's width, or 105mm. So it's a very rough estimate. These things are overkill, make no mistake, but everything smaller comes with M6 screws and my existing cables already have 8mm lugs on them. The BMV shunt is even bigger.

Will take a picture a bit later. I don't smoke so there is no smoke-break excuse to venture out to the car... but I'll do it anyway :-)

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Will take a picture a bit later. I don't smoke so there is no smoke-break excuse to venture out to the car... but I'll do it anyway :-)

Sent from my GT-I9195 using Tapatalk

[Mark]

I see what you mean... serious kit...;)

Thanks

[superdiy]

3 hours ago, plonkster said:

 

Like your backdrop.  

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18 minutes ago, superdiy said:

Like your backdrop.  

It's the back of the invoice, an A4 sheet, lying on my car's passenger seat. It's actually meant for scale (since presumably everyone knows an A4 sheet is 297mmx210mm?).