What size lugs
- Thread starter leemc82
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OffGridInTheCity
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Welcome to the forum 
For what it's worth....
I use 6awg bare/twisted copper https://www.wireandcableyourway.com/6-awg-soft-drawn-stranded-bare-copper-wire for my buss bars... and use 2awg lugs https://www.amazon.com/gp/product/B06XKY75XJ/ref=ppx_yo_dt_b_search_asin_title which fits 2 x 6awg in for crimp very nicely.
Then I beat them with a hammer so they'll lay flat on the packs - which is why the lug looks 'flattened' in the pic.
For what it's worth....
I use 6awg bare/twisted copper https://www.wireandcableyourway.com/6-awg-soft-drawn-stranded-bare-copper-wire for my buss bars... and use 2awg lugs https://www.amazon.com/gp/product/B06XKY75XJ/ref=ppx_yo_dt_b_search_asin_title which fits 2 x 6awg in for crimp very nicely.
Then I beat them with a hammer so they'll lay flat on the packs - which is why the lug looks 'flattened' in the pic.
Might help if you untwist each bunch an inch or so, then make one round bunch of the strands so it fits in the lug more easily?
Whatever lug you use, try to find ones with the hole size already matching the bolts, enlarging the hole not good (not allowed in regs as it reduces current handling).
Whatever lug you use, try to find ones with the hole size already matching the bolts, enlarging the hole not good (not allowed in regs as it reduces current handling).
italianuser
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Welcome to the forum... I'm destroying my fingers making the busbars for my battery!
Great forum. I am still in the early stages. Slowly building up my system which will be 80P 7S initially. For those of use who are metric lol.
I am using 10mm2 earth cable stripped and 16mm lugs with a hydraulic crimper. Once I have the 7 packs all done like this, I will start soldering the fuse wire onto the cells.
I am using 10mm2 earth cable stripped and 16mm lugs with a hydraulic crimper. Once I have the 7 packs all done like this, I will start soldering the fuse wire onto the cells.
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italianuser
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I'm using SC10-8 copper lugs for my 10mm2 wire (7AWG) connecting series. The cable/lug choice is based on my initial project where I defined:
- Single battery will be 14S20P, average cell around 2100mAh, total capacity around 42A;
- At any time a single battery will charge/discharge no more than 20A (so each battery will have 20A fuses and 20A DC MCB);
- Four batteries 14S20P will be in parallel, at any time: one out of four can go in maintenance leaving three batteries operational.
[ Note: on the first 14S20P battery I made I used SC16-8 lugs, actually a bit too big, now I switched to SC10-8, the right size. ]
- Single battery will be 14S20P, average cell around 2100mAh, total capacity around 42A;
- At any time a single battery will charge/discharge no more than 20A (so each battery will have 20A fuses and 20A DC MCB);
- Four batteries 14S20P will be in parallel, at any time: one out of four can go in maintenance leaving three batteries operational.
[ Note: on the first 14S20P battery I made I used SC16-8 lugs, actually a bit too big, now I switched to SC10-8, the right size. ]