AndrewBrown said:
1. If busbars will be 1/8" Thickness, 1/4" Width - is it enough?
2. To be honest I didn't catch regarding "Just connect 2-Pos and 2-Neg that are adjacent to each other (ie, row 1, 2, 3 & 4), and then on the flip side, you add the next section starting with row 3 (ie row 3, 4, 5 & 6)" .Is it possible to show on the drawings?
1) That would probably be sufficient, yeah. It's about cross sectional volume to carry current. With 1/8 x 1/4 would give you approximately 105A capability. Remember, current will flow through the "entire" string of cells, not just added up at the ends (this is voltage). That would give you a very good margin to keep hot spots down. You could even go with a thinner material perhaps and still be fine. A 1/16 x 1/4 would give you about 70A.
2) Basically it's what your second drawing is. The blue lines connect the opposite side. The only reason I said 4 rows was because you had 2x20 arrangement. Had you had 1x40, then I'd said connect rows 1 & 2, 3 & 4, on the one side, and connect 2 & 3, on the other side. For each section of the series, you connect Pos to the Neg of the next section.