Flexible Busbars for Battery Energy Storage (BESS)

Why Flexible Busbars in Energy Storage?

BESS cabinets and PCS enclosures carry high continuous currents in the tightest of spaces. Rigid copper bars cannot compensate for the stack tolerances between modules or for thermal movement. Especially in outdoor containers, where ambient temperatures can range from −20 °C to +50 °C, the resulting expansion is considerable. In operation, rigid connections in this environment can lead to rising contact resistance, heat build-up at the connection points and, in the worst case, safety shutdowns.

Flexible busbars provide compliant, low-resistance connections between battery racks, DC busbars, PCS modules and AC outputs. The press-welded copper foil construction achieves the current-carrying capacity of solid copper and keeps contact resistance stable even after thousands of charge/discharge cycles. In sealed BESS cabinets, where every additional heat input worsens the derating factor, stable contact resistance is a safety requirement.

For BESS applications, tin-plated copper busbars with heat-shrink or PVC insulation, designed for continuous operation, are recommended. For DC busbars and PCS connections, cross-sections up to 4,000 mm² and rated currents up to 10,000 A are possible.

Applications

Rack-to-PCS connections
DC busbar connections
Module-to-rack connections
AC outputs in PCS cabinets
Solar-plus-storage installations
Containerised large-scale storage

Technical Data

Parameter	Specification
Rated current	100 A – 10,000 A
Voltage	Project-specific, typically up to 1,500 V DC
Conductor material	High-conductivity copper (purity ≥ 99.9%), e.g. Cu-ETP, Cu-HCP or Cu-OF (OFC), as required
Lamination thickness	0.1 – 0.5 mm
Cross-section	Up to 4,000 mm²
Surface	Tin-plated; others on request
Insulation	Optional, e.g. polyolefin heat-shrink sleeving or PVC
Operating temperature	Depending on insulation material

Custom Busbars for Your Energy Storage System

Send us your drawing or your requirements for current, voltage and installation space. We manufacture flexible busbars for BESS integrators and PCS manufacturers worldwide.

Inquire now

Need advice? Our experts assist you in choosing the optimal solution for your application.

Kai Kleinevoß

Head of Sales Wirbalit®
kleinevoss@svs-schweisstechnik.de
+49 208 99 328 15

Flexible Busbars for Energy Storage