I'm setting up a battery system with 16 EVE 3.2v 150ah LiFePO4 cells connected in series. I'm wondering if aluminum bus bars will suffice, or if I should opt for copper instead. Also, what thickness should these bars be to handle the load properly?
3 Answers
One concern with aluminum is its susceptibility to corrosion and the way it expands and contracts, which can cause connections to loosen over time. This can lead to increased resistance and even potential hazards. If you decide to go with aluminum, consider using tinned or silver-plated options for added safety. It's worth noting that aluminum isn't too common in household wiring anymore for good reasons.
Copper is typically the go-to option since it's very efficient, but aluminum can work just fine if you size it correctly and make sure the connections are secure. You can find calculators online to help determine the right dimensions based on the electrical loads you're dealing with.
I built a battery shelf using a long aluminum bus bar to save some cash—the copper was way pricier! I just made sure to size up the aluminum enough to match the current rating. I ended up using 0.5" x 2.5" aluminum to handle around 400 amps. By the way, did your battery cells come with flexible bus bars already?