Battery terminals, busbars and balance cables - How I do it! Building a 48v/14kWh battery. Part2

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There is a lot to discuss when it comes down to how to connect single cells to a battery. What is actually correct and what not. What should you do and what not. I guess there are a million ways you could to it. In this video I show you how I do it and explain why I do it this way. If this is correct or not... who knows?
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5 мар 2022

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Комментарии : 98

@MrHoolign Год назад

I love when I find a new channel like this! Just like you said Andy, there are a Million ways to do these setups.... and when I find a big Brain like you, similar to Everlanders Jason but very different, it just makes my day. I've been watching for a few months and now getting into double views since I'm beginning to understand. Great Job! Great attitude! Great Channel! Keep on keeping on

@marcobrian1619 2 года назад

I'm so pleased for you Andy, at last the end is so close...... Really hoping your channel will carry on after the battery bank is complete.

@excillisbank2611 2 года назад

Super j'adore l'approchetechnique et la schématique Andy, merci pour ce partage.👍

@greengooseman 2 года назад

First 15 seconds was pure eye candy. Im hooked.

@gumpster6 2 года назад

Thanks for sharing this with all of us. It's a lot of work but worth it.

@TrevorFraserAU 2 года назад

Thanks again Andy, hope things are as well as can be expected at the moment for you over there. Holding thumbs your Interwebs get sorted soon.

@mdunbar04 2 года назад

Great Job Andy. I see you have your Lil helper Diego for the late night work in the Garage

@john_in_phoenix 2 года назад

The locktite really helps. I polish my terminals, but with a felt wheel on a dremel soaked in alcohol.

@jimmysquires5093 2 года назад

Andy, another idea on connecting your balance leads without the possibility of striping the buss bar. Bring the screw up from under and use a nut on top. This will also make it easier to get a small wrench to tighten them up rather than a screw driver.

@burnzy56469 2 года назад

Nice Andy. Your going to beat me iv got my first 14s running. Just started putting the fuse wires on my second 14s. I'm doing the old 18650 build my 1s is 260p it's a lot of work I'm going to build 3x 14s packs and that's it once there dead I'm going to go to the lifepo4 prismatic cells like you.

@rahsomali 2 года назад

Hahaha we’re just gonna ignore polishing the bus bars 🤣👌🏽. These videos are starting to feel like you’re teasing us Andy. Cmon.

@millzee60 2 года назад

Loving the Fractal Of Light, Chris Haugen :)

@NB-ld1qt 2 года назад

Good work Andy. I may have missed something in a previous video. Where is the smart shunt now for this battery bank ?

@solargarage 2 года назад

Looking beautiful Andy

@vickipps6821 2 года назад

It's realy looking great and very neat

@rattusfinkus 2 года назад

Hi Andy, have you heard about High current and hostile environment copper connections jointing compound? CABAC makes it it's called EJCC/220 and you can get it from electrical wholesalers in Australia. It's got copper powder in it.

@mondotv4216 2 года назад

Hi Andy - where did you get the grub screw studs for the battery terminals? Another great vid.

@joshg1244 2 года назад

Nice work!

@MrRossi1805 2 года назад

Danke für Deine Ansichten :-)

@defjamsgreen 2 года назад

WELL ALRIGHT ! ALMOST READY TO OFFICIALLY HIT THAT OFF GRID SWITCH .

@Dutch_off_grid_homesteading 8 месяцев назад

Heya, hope the rain will soon end, and hope you can turn on this new battery for the 1st time with the inverters

@kswis 2 года назад

Looks excellent

@David_11111 2 года назад

WOW YOU BROKE IT !

@unionse7en 2 года назад

Similar to appling flux, if you abrade the metal while the compound covering the surface, the freshly prepped surface won't have a chance to be exposed to ambient air. The compound can be applied while scrubbing with an abrasive pad like scotch bright to achieve this. "Roloc" rotary bristle brushes could work also. After abrading with the anti-oc compound, wipe it off , to remove the debris. Don't use a solvent.. so that you retain a thin layer of the compound, then apply a minimal amount more of fresh compound and assemble.

@OffGridGarageAustralia 2 года назад

That's what I have done today. Testing it right now...

@wtpenn 2 года назад

I noticed how neatly trimmed your sensing leads are . Is it permissible to cut the leads to length ? I will be using a Daly 4S12V BMS , and would like to trim the leads to length . Will that cause any issues ?

@patrickgeers1 2 года назад

Swing the negative busbar coming from the battery a quarter to the right 👍

@davidkettell6236 2 года назад

i had the same hydraulic crimper ,only good for lightweight use , Mine broke the third time i used it in exactly the same place . it will not crimp Anderson connectors.

@KPTnVAN 2 года назад

Andy, be carful!!! The case of the cells are connected to minus! And the foil around them is very thin!!! Placing on an aluminium plate and touching together can cause a catastrophe!!!!

@wiedapp 2 года назад

There is a sheet of acylic between the shelf and the cells. Well documented in the build series of the shelf.

@chronzz 2 года назад

@@wiedapp yup

@chuxxsss 2 года назад

Morning Andy, how is it going up there? Water dropping. I work out for 300 A you need a busbar of 10 mm think and 40 mm wide?

@fldutch 2 года назад

Come on - get that printer. Got mine 5 years ago and thinking about a new one, because mine only can do PLA and not ABS. So many things to do with a 3D printer - e.g. fixed a broken broom attachment to the stem, many things for my model railway etc. Would not like to miss it - it's like a swiss army knife. You could even print lots of covers for busbars, terminals, whatever. Get it. Oh, an there is a RV company in germany (WCS) who also got a 3D printer, because they where annoyed paying so much money for temperature sensor casings (which also were short on supply by the manufacturer) - as a side effect the printer is on duty nearly 24/7 because the also print mounts for internet routers, cable bushings and other things. Get one :).

@haydenwatson7987 2 года назад

Rather than having the torque from tightening the nuts go to the terminal treads, have you considered using an Allen screw to hold the grub screw when you are tightening. You can still use the torque wrench but using a crow's foot socket. You will need to do a bit of math to adjust for the extra leverage due to the distance from the center of the crow's foot to the center of the grub screw but once you have the number, all is good.

@jmaus2k 2 года назад

It's almost like you have done this before. "I would never polish terminals".... LOL. You can just use some extra conduit with a slit to cover those exposed terminals. Or just bend some plastic with a torch and vise. It isn't that hard to make bend if you want to spend the time on it. Looking great.

Месяц назад

What value fuse did Andy use on the sense/balance lines?? I am thinking 2 amp 125vdc.. It sure would be easier to replace an external fuse compared to replacing the surface mount .01 ohm 1/16 amp chip resistors they have on the board which act as 2.5 amp fuses.. I plan to use a light film of De-Ox-It gold on all the terminals and crimp ends where connections are bolted together.. That stuff will prevent oxidation for a decade at least and is supposed to increase conductivity of metal to metal connections.. I also plan to put a film of liquid flux on the copper cable ends and inside the copper crimp cups then flow solder into that after I crimp them down..

@OffGridGarageAustralia Месяц назад

That depends a bit on your BMS and used balance current. The JK has already 2A of balance current, so I chose a 5A fuse for each balance cable.

@randrcomputers 2 года назад

Exciting! :)

@Knightliner69 2 года назад

Check out the „Sicherungsklemmen“ from PhoenixContact. So you would have them all located at the terminal and you can get them for a lot of fuse types. No filigrane glas fuses needed.

@wiedapp 2 года назад

I had them in mind at first, too, but the length of wire from the cell to the fuse terminal would have to be special wire, that is 'kurzschlussfest', because that length of wire would still be unfused.

@davidpenfold 2 года назад

Nearly there!

@Bastler95m 2 года назад

I think fuseholders would have been a better bet than those tiny fuses you soldered in to the wires directly. I never had anything to do with batteries that have aluminum terminals, but I had connected some aluminum cable on a distribution board for a gas genset and it was recommended to scrape the wire off with a knife and than put aluminum contact grease on the wire and then put them in to the terminals.

@OffGridGarageAustralia 2 года назад

You use fuse holders if you expect the fuse to blow more or less frequently. I'm not expecting to replace the fuses at all. EVER! (that's a mouth full!)

@Bastler95m 2 года назад

@@OffGridGarageAustralia ok, that's another point of view, my thought was more like ease of replacement or even the possibility of easily upgrading the fuses to a higher amperage that the wires still can take.

@anonym7196 2 года назад

Why are you not using a Batrium bms? like the BlockMon M8?

@SkypowerwithKarl 2 года назад

Batriums are pretty much top of the line but that JK BMS is proving out to be the best economy unit on the market. 200 amp both ways and a start voltage programmable 2 amp super capacitor balancer is hard to beat.

@edwardvanhazendonk 2 года назад

Sweet dreams and have a nice night to recover from hard work!

@danfitzpatrick4112 2 года назад

I don't understand the fuses on the balancing leads. I would think that may cause issues if for whatever reason one would blow. I could see protection on the main balancer to all batteries I suppose but this may even already be inside the unit? Just curious...

@peters619 2 года назад

I think they aren’t fuses - they are mini bus bars that allow the BMS to be removed without disturbing the battery for maintenance and safety as no loose leads would be left lying around.

@teddypreston5525 2 года назад

I am curious if the distance between cells needs to be kept equal? And if so, within what tolerance? Shouldn't we have used some kind of spacers (plastic, cardboard, etc.) between cells in order to make the connecting bars equidistant so the 5amps fuses will all react in the same manner: I am just saying.

@mondotv4216 2 года назад

The fuses are just for the balance leads. It’s much more important to have your main buss bars all about the same length and therefore resistance as they carry a much higher current.

@ricardomarcelino8388 2 года назад

Great to see the progress Andy. I was wondering, what is the resistance for the aluminium buss bars? Are they better than the pure copper ones? I can see they are far thicker, but how does that affect resistance after all? Stay charged and a big hug from Madrid-Spain!

@jmaus2k 2 года назад

Removing the oxidation layer is more important for lower resistance on these small bussbars than difference between aluminum or copper. Aluminum or copper bars should be good, but the brass coated steal are bad.

@rahsomali 2 года назад

Aluminium has higher resistance than copper regardless. Pure copper is the way but aluminium is second best.

@unionse7en 2 года назад

Just have to increase the area to make up for the conductivity difference (per area). That and protect from oxidation at the interface.

@ricardomarcelino8388 2 года назад

Sure! But I see the bussbars are quite thick, when compared to regular ones that come with the cells. I am just curious about the resistance in the ones Andy is using, so I can have a rough idea of how much difference is involved. Andy, can you do a test on resistance? Those aluminium buss bars (bussbars?) are sexy!!! 😍😍😍

@unionse7en 2 года назад

@@ricardomarcelino8388 , they are thicker so that they end up being the same resistance as a smaller copper one of course.

@sergeyblinov4957 2 года назад

Concerning hydro crimper. Such a fault of crimper is "preprogrammed" by design flaw. Also, I suggest, that protective valve (the one with rotating knob) has failed, and its failure led to excessive force in press area.

@markobotz2890 2 года назад

Hi Andy, I have a personal question, did you do some pool videos before you moved down under? I'm not quite sure but I think we had some conversations on the poolpower-shop forum before, is that possible 🤔 all the best from Germany, Marko

@OffGridGarageAustralia 2 года назад

No, that was definitely not me!

@balazssztreha6796 2 года назад

I would wrap the screws and metal tools with eletric tape or something to prevent drop and short the battery 7:38

@SkypowerwithKarl 2 года назад

Absolutely! It’s happened to me even though I was being careful and thinking about it. Excrement events eventually

@NaughtyGoatFarm 2 года назад

Have the same hydraulic crimper if you need to borrow it.

@Kotttek-du3mi 2 месяца назад

Do you have fuses on battery leads?

Месяц назад

He has a large DC breaker that is on both the B+ and B- before those lines go to the buss bars..

@ripmyjeans 2 года назад

fireworks? maybe it was a rescue flare (i'm thinking like scene from Titanic) from a neighbor on one of the other house shaped boats in the middle of the big lake :-)

@OffGridGarageAustralia 2 года назад

Oh $hit, I didn't think about that 🎆

@SinKillerJ 2 года назад

At least if you were going to break something, you made it look really impressive.

@svens.5588 2 года назад

I still don't understand why you don't place the main positive at the rear of the shelf. The cable would be shorter, you have more Options to tighten it and you don't have both poles so Close together.

@BenCos2018 2 года назад

@WhatsApp me+❶❽❶❸❺❸⓿❻❷❼❽ lmao nice try scam bot

@CollinBaillie 8 месяцев назад

You should 3D print a bracket with air spacing for that BMS, you just need a 3D printer! 😉

@gewema-makkum 2 года назад

To fuse or not to fuse ? the BMS lines.. 😄 I personly do not do this.. Looking for trouble... especialy fragile glas fuses.. It's also not recommend or mentioned by the big BMS manufacters..

@user-uc6mp3it1c 2 года назад

But the fuses between the terminal and the BMS not in the battery Baspar

@SkypowerwithKarl 2 года назад

Andy, those aluminum buss bars may need to be lapped on one side to get all the oxide off. That hand cleaning may not be enough. I’d get a sheet of 400 or 500 grit and put it on something flat like a new pane of glass to lap them on. Since the aluminum oxides very quickly I would probably be a good idea do half at a time. I’d lap (Not polish) the terminal tops too with a lapping tool. See my video “ LiFePO4 terminal, buss bar and lug preparation”. It’s important to clean any oil or grease off the surfaces before lapping. Also clean off the lapped surfaces when done with alcohol and inspect carefully for lint or debris before assembly. I use a small amount of Noalox too. Easiest way is to put a gob into a plastic bag and snip off a very tiny corner and put it directly on the terminal surface. If it’s on the bars it’s too easy to accidentally get it on the threads (my hands are too shaky). If it gets on the threads you can greatly increase the tension on the studs when you torque lubricated nuts. How do you know if the buss bar installs are good? I’ve found the internal resistance meter only to be a “fair” indicator but measuring actual voltage to be the best. I put a probe on the battery terminal just under the buss and the other just over it on the top of the buss and measure. What I consider good is anything less than .0005 volt (that’s right, half a millivolt) at a 50 amp load.

@jmaus2k 2 года назад

Check Andy's videos from last year. He was joking when he said he would never brush or clean terminals ....like over and over...for 5 videos. LOL. Ray Builds Cool Stuff also did a good job with testing optimal terminal to bussbar connections and is using a similar antioxidant paste.

@SkypowerwithKarl 2 года назад

@@jmaus2k Yeah I know, just won’t let him forget it. lol! If that’s the biggest mistake then he’s a genius lol.

@geraldkoth654 2 года назад

I really think Digital Mermaids crimped copper cables are best.

@opless 2 года назад

NINETEENTH!

@opless 2 года назад

And the WhatsApp reply has been reported! GG THX BYE

@edwardbyrd7667 2 года назад

Say hi to Diego for me

@davestech6357 2 года назад

One battery link should be fused for protection.

@happymike8 2 года назад

I agree with that too, I have a 250 amp fuse in the middle of my 600 ah gel cell pack, but that has no BMS. I wonder what would happen to the BMS, if a momentary short on the output, suddenly applies 52 volts to the BMS monitoring leads between cells 8 and 9 (where the fuse would be), when it's only supposed to have less that 4 volts. Could destroy the BMS methinks! So I will just stick with the BMS and a circuit breaker for protection, and mechanically protect the battery pack, and use insulated tools.

@chuxxsss 2 года назад

Should I sleep ride to where I am going? Sweet dreams, I am here.