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Paul, I made one shunt today. The manganin was almost 1 1/4 inches wide by .060, so I made two sets of taps, one at 0.1 milliohm and one a bit short of .2.The current tabs are just the extension of the manganin strap,
If this and an instrumentation amplifier replace the noisy Hall device, some serious reduction of the resistance between the measuring leg and the current connections will be needed. I roughly calculated the total dissipation of this one at 1000 amps to be 500 watts. Over 100 watts at 500 A. Only the area between the sense leads needs to be manganin, so I figured to silver solder copper pieces on each end for the current connections if it is to be a operating component of the controller. This one was planned to give Paul a way to look at battery current in testing. Give feedback; I can do more. Vista Metals was generous and I have the oxyacetylene torch, silver solder, and copper.
bob
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