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Battery Series/Parallel connection guidance

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dax021:

--- Quote from: mihit on February 04, 2022, 09:49:25 PM ---I make "bus-links" by hammering 1/2" copper pipe flat and drilling required holes. Good for a couple of hundred amps. 3/4" pipe would give you a bit more again.
You can then insulate with heatshrink or tape.

And I would make them all the same length/ gauge, but it probably isn't neccessary.

--- End quote ---

I do the same, 1/2" Cu pipe.  Never bothered with the heatshrink though

BruceM:
Flattened copper pipe is great, but there is also 16 oz/SF copper flashing to consider. Amazon carries it.  I use it for HF grounding systems and connections to same, and also for high current strips and straps on power PCBs, etc.  Handy stuff.

https://www.amazon.com/Copper-Flashing-Contractor-use-Lead-Pressure/dp/B07MYMMK17/ref=sr_1_2?
keywords=copper%2Bflashing&qid=1644014251&sr=8-2&th=1


dax021:

--- Quote from: BruceM on February 04, 2022, 10:39:38 PM ---Flattened copper pipe is great, but there is also 16 oz/SF copper flashing to consider. Amazon carries it.  I use it for HF grounding systems and connections to same, and also for high current strips and straps on power PCBs, etc.  Handy stuff.

https://www.amazon.com/Copper-Flashing-Contractor-use-Lead-Pressure/dp/B07MYMMK17/ref=sr_1_2?
keywords=copper%2Bflashing&qid=1644014251&sr=8-2&th=1

--- End quote ---

You are 100% correct, that stuff is great, but rather expensive.  On the other hand, I have so many offcuts of Cu pipe lying around from my handyman work, that it is essentially free and would go to scrap otherwise.

As far as I know, stranded cable is still the most effecient option.  As I understand it, voltage flows along the outer sides of a conduit, so the more strands, the less resistance.  The higher the voltage the less the losses, but at low DC voltages it apparently makes a differnce.  In my case the cost doesn't justify the effeciency gain.

ThomasEriksen:
Skin effect only applies to alternating current, so nothing to worry about before you get over the kHz range, direct current use all of the conductor

BruceM:
+1 Skin effect is entirely an AC high frequency issue, and has no role in DC power connections.  Stranded wire (round or strap) only helps with flexibility for DC power.

I agree too that battery connection straps from flattened copper pipe are a great use of surplus copper pipe cutoffs.

For high frequency grounding, where ground strap length to width ratios of 4 or 5 to 1 are often recommended, copper (16 oz/SF) flashing sheet works nicely.   I also like to use the 20 inch wide roll material as part of the buried earth HF ground system.  Since I have leftovers I tend to use the copper sheet for lots of smaller bits.

   






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