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Insulated Flexible Copper Busbar for Battery Packs, 150A to 350A Continuous
Insulated Flexible Copper Busbar for Battery Packs, 150A to 350A Continuous
3 in stock
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- ✓ Cut to order in Michigan
- ✓ Material sourced from industry-certified supplier
- ✓ Ships in 3-5 business days
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Insulated flexible copper busbars for connecting your battery pack to the rest of the system. Use them anywhere a cable with two lugs would go: pack terminals to a fuse or breaker, shunt to BMS, BMS to bus bar, battery to inverter, or between battery boxes and modules. They are not meant for cell-to-cell series connections inside the pack.
Compared to cable, there are no lugs to crimp. The bar is punched and bolted directly, it bends and twists by hand to fit tight layouts, and it takes less room than the equivalent wire. The tinned copper resists corrosion and the halogen-free insulation is rated to 1500 VDC.
Each piece is cut and punched to order in Ann Arbor, Michigan.
How to pick a size. Pick by continuous current: the steady load your system draws for 30 minutes or more. The max rating is for short bursts only, so don't size to it. Replacing cable? The 150A size is about like 4 AWG, the 250A size like 1/0, and the 350A size like 4/0.
Specifications
- 150A continuous size (200A max)
- 150A continuous, 200A max
- Copper: 15.5 x 1.6 mm (24.8 mm², 49 kcmil, between 4 and 3 AWG)
- 1/4 in mounting holes
- 250A continuous size (350A max)
- 250A continuous, 350A max
- Copper: 24 x 2 mm (48 mm², 95 kcmil, between 1 AWG and 1/0)
- 5/16 in mounting holes
- 350A continuous size (500A max)
- 350A continuous, 500A max
- Copper: 24 x 4 mm (96 mm², 190 kcmil, between 3/0 and 4/0 AWG)
- 5/16 in mounting holes
- Made to order: ships in 5 to 7 business days
- Lengths: 2 to 12 in, measured hole center to hole center. Overall length is 1 in longer (0.5 in past each hole).
Current rating vs. installation
The max rating is for short loads (minutes, not hours). For continuous loads (30 minutes or more), the safe current depends on how hot the air around the bar gets and what it bolts to. Use the "fuse, breaker or lug" columns for runs to those parts. Use the "cell terminal" columns when the bar bolts straight onto a cell, because cell terminals should stay under 60°C.
| Where the bar runs | Ends on | 150A size | 250A size | 350A size |
|---|---|---|---|---|
| Open rack, room at 25°C | Fuse, breaker or lug | 200A | 320A | 470A |
| Open rack, room at 25°C | Cell terminal | 165A | 265A | 385A |
| Closed battery box, 40°C inside | Fuse, breaker or lug | 165A | 265A | 385A |
| Closed battery box, 40°C inside | Cell terminal | 120A | 195A | 285A |
In a hot shed or garage, size up one class. Bundled bars, bars laid flat, and loose or dirty joints all run hotter.
Technical details
- Conductor: electrolytic tinned copper (Cu-ETP)
- Insulation: TPE, low smoke, halogen-free, flame retardant
- Self-extinguishing: UL 94 V0
- Insulation elongation: 500%
- Dielectric strength: 20 kV/mm
- Nominal voltage: 1000 VAC / 1500 VDC (IEC/UL)
- Temperature range: -50°C to +115°C
- Insulation thickness: 1.8 mm typical
Custom orders
Need a length that isn't listed, a different hole size, or more than two holes? Send us a message with what you need and we will quote it.
Contact us for your custom order
Was trying to figure out how to bridge two oddly spaced terminals on a custom layout and these jumpers were exactly the right call. Flexible, well insulated, and the lugs are properly tinned. Will be ordering more for the next build.
Was trying to figure out how to bridge two oddly spaced terminals on a custom layout and these jumpers were exactly the right call. Flexible, well insulated, and the lugs are properly tinned. Will be ordering more for the next build.