CNC Machined C10200 OFHC Copper Terminal Block for BESS with 600A+ Current Rating

The terminal block serves as the central connection point in BESS cabinets, where DC strings from cell modules and power cables to inverters converge. As the most electrically stressed component in the system, proper contact resistance is critical to prevent thermal issues during commissioning.

C10200 OFHC (Oxygen-Free High Conductivity) copper provides superior performance compared to C11000, offering enhanced conductivity margins essential for handling 600A+ per connection. The oxygen-free structure ensures reliable performance at elevated temperatures where terminal blocks typically operate.

Our machining expertise addresses the challenges of deep tapped holes, flat contact surfaces, and tight positional tolerances in 2-5kg copper blocks. Through optimized tooling strategies, specific rake angles, chip breaker geometries, and peck cycles, we achieve exceptional tap life of 300+ holes per tap in copper alloys.

• High Conductivity: C10200 OFHC copper with ≥101% IACS conductivity — verified with certification on every material lot
• Deep Thread Quality: M6-M16 tapped holes with thread depth up to 3x diameter, chip-free and gauge-tested
• Contact Surface: Ra 0.8 finish on all current-carrying surfaces for minimum contact resistance
• Plating Options: Tin plating (standard for BESS), silver plating (high-current), or nickel barrier + tin (harsh environment)
• Hardware Integration: Installation of set screws, spring washers, and cable lug hardware per your BOM — delivered ready to bolt in
• Current Rating: Designed to handle 200-800A+ per connection point depending on cross-section and plating

• BESS Power Distribution: Central terminal blocks for DC string connections in battery energy storage cabinets
• Inverter DC Terminals: Heavy-duty terminal blocks for DC-side inverter connections in solar+storage systems
• EV Charging Infrastructure: Terminal blocks in DC fast charging power distribution units
• Industrial UPS: High-current terminal blocks for three-phase UPS systems in data centers and factories
• Solar Combiner Boxes: Terminal blocks for combining and distributing DC strings from solar arrays
• Telecom Power Systems: Terminal blocks for 48V DC power distribution in telecom shelters

• Copper Machining Expertise: Specialized processes for copper alloys including tooling, fixturing, and chip evacuation
• Thread Quality Guarantee: Every tapped hole is gauge-tested to prevent cross-threading in high-current circuits
• Plating Thickness Verification: XRF testing on every plating lot ensures specified thickness requirements
• Hardware Assembly Capability: Complete installation of hardware with proper bagging and tagging per part numbers
• Scalable Production: Consistent quality from first article to 10,000+ monthly production with ongoing engineering support

1. Design Review: Comprehensive analysis of thread depth, material thickness, contact surface accessibility, and plating compatibility
2. Material Procurement: C10200 OFHC copper from certified mills with conductivity test reports and MTR for every lot
3. CNC Machining: Multi-side milling with custom fixtures and rigid tapping using MQL for clean threads
4. Thread Gauging: 100% GO/NO-GO gauge testing on every tapped hole with serial number traceability
5. Plating: Tin, silver, or duplex plating per specification with XRF thickness verification and lot tracking
6. Hardware Assembly & Packaging: Installation of set screws, washers, and customer components with anti-tarnish packaging and desiccant