With respect to just "connecting" them, standard cables like you would
use for Lead Acid batteries work fine, typically with ring terminals (vs
clamp).
Size the cables based upon your amperage. If you are replacing a lead
acid pack, I'm going to assume 90-200 volts, and LOTS of amps, so you
probably want to use 00 welding cables.
Get crimp ring connectors sized for the bolts that go into your cells
and a hydraulic crimping tool.
However, you may find that the lithium modules are a lot smaller than
Lead Acid batteries, so need more connections (and the connections may
be closer together.
Also, many/most LiIon modules need to be kept under compression so they
don't swell during charging or discharging.
A solution I used was to package up the modules into "battery sized"
chunks, clamped together (threaded rod through plywood end pieces,
although you could use metal) with a copper busbar sized perfectly for
the "clamped" spacing of the modules. You don't want to use a solid
busbar between modules that can move relative to each other as it may
rip the bolt/terminal out of the module, but it's OK to do so far ones
that are physically clamped together.
Then I just used the (flexible) 00 welding wire to connect the
"batteries" together, much like the original Lead Acid.
https://www.youtube.com/watch?v=PjTwhR-DrqQ
You can find a lot more here by going backwards in age:
https://www.summet.com/blog/tag/etruck/
Jay
On 2/24/26 01:42, Daniel Eyk via EV wrote:
I recently sent an email about lithium batteries and I want to thankyou for
replying as
it helped me a lot.
I have a followup question about how to hook up the lithium batteries and
what
parts are needed to do that. I am used to the old lead acid batteries and
after looking
at my battery box, I realized that I don't know how to connect the
batteries.
Also, someone asked me what kind of lithium batteries I have. They are
Calb lithium ion batteries. They have a red cap and a black cap and there is
a barcode with this number on it. NSA 601305040234. I don't know if that
will
help or not in identifying the batteries, but that is what it says.
Well, if anyone can tell me what parts I need and maybe cables, I
would appreciate it. I did get around $300 worth of cables based on my
knowledge of lead acid batteries and hate to lose that value, but you
can't have everything.
Thanks in advance for any information you can provide.
Dan Eyk
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