Accurate current and voltage monitoring is essential for modern power electronics, battery systems, and energy projects. This project presents a DIY Smart Shunt capable of measuring up to 80V and 100A DC, designed for reliable, real-time power monitoring with a compact and professional PCB layout. The smart shunt combines high-current sensing with a microcontroller-based interface, making it suitable for DIY power systems, solar setups, battery monitoring, and lab applications.

Project Overview

The DIY Smart Shunt is designed to measure:

• High DC currents (up to 100A)
• DC bus voltage (up to 80V)

A precision shunt resistor is used to measure current flow, while onboard signal conditioning and processing ensure accurate readings. The board integrates communication pins for easy interfacing with external controllers or displays. The compact form factor and screw-terminal connections make installation simple and robust, even in high-current environments.

Key Features

• Supports up to 80V DC measurement
• Handles 100A continuous current
• Precision shunt-based current sensing
• Compact and well-isolated PCB design
• Clearly labeled terminals and test points
• Designed for DIY and professional use

How It Works

At the heart of the system is a precision shunt resistor placed in series with the load. As current flows, a small voltage drop develops across the shunt.

1. The voltage drop is amplified and conditioned
2. The onboard controller measures this signal
3. DC bus voltage is measured simultaneously
4. Data can be transmitted to an external system for monitoring
5. This method allows accurate current measurement without significantly affecting the power system’s efficiency.

Results

The final board delivers stable and repeatable measurements across a wide voltage and current range. Its compact size and clear labeling make it easy to integrate into both experimental and permanent installations. The design proves that high-current measurement solutions can be built affordably without sacrificing performance or safety.

Conclusion

The DIY Smart Shunt 80V | 100A DC by Steve Willson Kujur is a powerful and practical tool for anyone working with DC power systems. With its thoughtful PCB design and robust current-handling capability, it stands as an excellent example of community-driven hardware innovation. This project is especially valuable for makers, engineers, and students looking to understand and implement real-world power monitoring solutions.

Credit & Acknowledgement

This project is shared for educational and community reference purposes.

Complete Design & Engineering Credit: Steve Willson Kujur

This article is shared to respectfully acknowledge and highlight the original creator’s work within the PCBWay community, encouraging learning, experimentation, and collaboration.