Need some battery connection suggestions.

[itsmoked]

I have to connect sixteen 2AWG cables probably with lugs with 5/16" or 3/8" holes unless someone has a lugless solution.

These batteries have odd terminals that are 0.560" in diameter and about 2" long.

I need a 200Amp connection between the cable and the battery terminal.

Some sort of split tube?
Some sort of split bars with a a trench in their faces?
Slit block with a hole thru the center?



Keith Cress
kcress -

http://www.flaminsystems.com

 

[IRstuff]

You would need to maintain equivalent cross sectional area, so I could imagine some sort of vertical busbar that terminates into a vertically extended conventional battery terminal clamp.
It would need to be mechanically supported, since 16 2AWG cables would put a lot of torque on the battery terminals.

Is this instantaneous 200A load or steady state? On each cable or total?

TTFN (ta ta for now)
I can do absolutely anything. I'm an expert!

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[John2025]

Not sure I completely understand what you mean, but if you have batteries that have a .560"diam x 2" post then maybe you could drill out a JIS pencil post terminal clamp to .560".

 

[itsmoked]

John!! That may be the ticket.

That's 0.504" and 0.571": negative, positive respectively. My posts aren't tapered so I'd definitely need to drill them out. Drilling lead or zinc, Oh boy!

Except you can't seem to buy any terminal clamps for JIS in the US.

Not following you IR.

200A continuous.

Keith Cress
kcress -

http://www.flaminsystems.com

 

[FacEngrPE]

There are adapters available. Battery Post Adapter for JIS (Pencil Post) to SAE

 

[itsmoked]

Saw those but they're most definitely for tapered posts on both sides which isn't the case here.

Keith Cress
kcress -

http://www.flaminsystems.com

 

[v6racer]

Looks like you can use lead or copper shims around the post to build up the diameter to the required size.

 

[RedSnake]

“Logic will get you from A to Z; imagination will get you everywhere.“
Albert Einstein

 

[kontiki99]

Easy to find specs and data. Just have to ensure ok for the operating environment. First hit
See ->

https://www.ask-power.com/blog/bid/331178/mil-spec-terminal-and-splice-standards-mil-t-7928g-ms20659

My posts reflect my personal views and are not in any way endorsed or approved by any organization I'm professionally affiliated with.

 

[itsmoked]

Ummmm...tiki.. I see nothing that comes close to my connection problem.

I've decided to go with a standard 8AWG-250MCM mechanical lug used backwards bolting the cables with standard swaged lugs to the mechanical lug. The hole the setscew normally clamps to the cable will be what I clamp to the battery terminals.

Keith Cress
kcress -

http://www.flaminsystems.com

 

[IRstuff]

Keith, was that last post in the intended forum?

TTFN (ta ta for now)
I can do absolutely anything. I'm an expert!

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[kontiki99]

There are other battery connect disconnect systems, such as those use on aircraft. For those to work, you would need a battery set up with that type of connector. This might be worth it if you expect to regularly disconnect and reconnect the battery. They are designed for it.

See ->

https://www.industrialmanlifts.com/product/aviation-battery-connectors-2/

My posts reflect my personal views and are not in any way endorsed or approved by any organization I'm professionally affiliated with.