How to connect the copper rods of the small busbar

A copper rod can be securely connected to a small busbar using bolted, clamped, or crimped connections while ensuring proper contact area, pressure, and safety precautions.Safety FirstBefore starting, de-energize the system completely and verify with a multimeter that no voltage is present. Wear insulated gloves and safety glasses to prevent electrical hazards during installation .Preparing the Copper Rod and BusbarClean the contact surfaces to remove oxidation or dirt. Avoid acid cleaning; simple mechanical cleaning or a wire brush is sufficient .Ensure the contact area is sufficient: for branch connections, the contact area should be at least five times the cross-section of the rod to maintain low resistance and proper heat dissipation .Connection Methods1. Bolted JointOverlap the rod and busbar and drill or use pre-punched holes.Insert a bolt with flat washers and a nut through the overlap.Tighten to the manufacturer's recommended torque to ensure even contact pressure without exceeding the bolt's elastic limit .Bolted joints are versatile and reliable but may slightly distort current flow due to the holes.2. Clamped JointPlace the rod against the busbar and use a clamp plate with bolts to secure it.This method avoids drilling, maintains uniform contact pressure, and reduces joint resistance .Ensure the clamp is sized appropriately for the rod and busbar thickness.3. Crimped or Compression ConnectionSlide a terminal lug over the stripped end of the copper rod.Use a high-quality hydraulic or ratcheting crimper to compress the lug onto the rod fully .Attach the lug to the busbar with a bolt or screw, ensuring proper torque. This method is common for smaller rods and high-current applications.Final ChecksVerify that the connection is mechanically stable and that there is no movement.Check that the torque on bolts or clamps matches specifications to prevent loosening under thermal cycling .Optionally, mark the connection with paint or a tell-tale to monitor loosening over time .If required, insulate the joint with heat shrink tubing or protective covers to prevent accidental contact . By following these steps, the copper rod will be securely and safely connected to the small busbar, ensuring reliable electrical performance and minimal resistance.

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This makes me conclude that bolts are not meant to carry current, and are really only for holding the two busbars together. Copper would be the best

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How to connect the copper rods of the small busbar