Making busbars for my Li-ion batteries.
Jon (Mar 31, 2022), nova_robotics (Mar 28, 2022)
I have a couple of mig welders with magnetic contactors in them the contactors in the machines when new were just 40 amp 2 pole with buss bars on both sides and would wear out rather quickly in 1 of the machines, so I went to 70 amp 2 pole, which lasted longer but still I felt the contacts were undersized. The largest contactor that would physically fit in the space was a 3 pole rated for 100 amps I made buss bars for it. That contactor has been in there for 4 years and I have a spare on the shelf for when it finally fails. The other machine is smaller but is seldom used at its max amps so the 70amp contactor I put in it has been working fine for quite a while now
Never try to tell me it can't be done
When I have to paint I use KBS products
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The busbar in this case is more of a bridge between the 3 poles of the circuit breaker, The amperage of the breaker would be the limiting factor. The number of batteries are irrelevant as long as you are not trying to use a breaker of this type to parallel batteries together it is for down stream output only never as an inter bank connector. circuit Breakers are also not meant to be used as switches while under load
Never try to tell me it can't be done
When I have to paint I use KBS products
My busbars are good for 120 amp per pole. In my case I am using lithium ion batteries which has low output current compared to lead acid. On your breakers there would be an IC rating usually between 3 and 15kA. That is a limiting factor on the breakers when using batteries. Lead acid can exceed 1000Amps easily under short circuit conditions. Always make sure that your total CC currents of your batteries do no exceed the IC ratings of you breakers. The busbars you have should have a current rating stamped on it unless you made it yourself. There is is quite a lot of considerations to take into account like temperature, insulation, enclosure type etc. which influence the outcome. There are charts available to put you in the ball park.
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