Battery-inverter cables upgrade

[pudding]

Ha, so which one is it? Pros and cons of each way? I'm sure there must be a giant thread somewhere about this. I'll do some searching.

[nowty]

Ha, so which one is it? Pros and cons of each way? I'm sure there must be a giant thread somewhere about this. I'll do some searching.

The Pylontech way is the simplest but its a compromise as the outer batteries will supply slightly more current than the inner ones because of the increasing resistance of the interconnect cables.

The Victron way keeps the current from each battery as identical as possible by keeping each cable length to each battery (including the interconnects) the exact same length.

[pudding]

Cable arrived yesterday. Here's the mass of 1m.


Ordered 50mm lugs too, both 6mm and 8mm. Just tried crimping those on with the new crimper that arrived yesterday too, and also found as someone previously mentioned that the 50mm profile didn't fully crimp and secure the lug as it barely compressed it, so needed to use the 35mm die to fully get it tight so it wouldn't pull off. The wires did only just fit inside the lug though, I doubt I'd have been able to get a 35mm lug on the end before crimping.

[Richard77]

Hi pudding...

Are you happy with the quality of the cables and lugs from superlecdirect?

Looking at purchasing some lugs and cable.

Thanks.

[pudding]

Hi, seems like we're on the same mission at the mo!

Yes, the cable seems good quality so I'd buy it again. Lugs were a good price and I've crimped a couple on already using what seems like the same crimper you've just ordered from ebay too, just I had to use a smaller die on the crimper to get a good tight connection.

One thing I don't have is a cutter to cut the 50mm cables I've got so I just ordered this - https://www.amazon.co.uk/dp/B0D87HW5H5/ ... _item?th=1
so I can cut the 1m lengths into 2, to go from inverter to DC disconnect, then on to a busbar/joining box.

I have a few of these spare - https://www.cef.co.uk/catalogue/product ... lsrc=aw.ds so instead of a busbar was thinking of just feeding the cables in there, the 1x50mm cable from DC disconnector, with the 2x25mm battery cables, and just putting a bolt through the M8 lugs on each cable to join them? Think it was suggested on here somewhere as an alternative to a busbar?

Edit: actually, i think I'll be able to simply fit 2 of the 25mm battery cables with M8 lugs straight into the Keto battery disconnector, saves the busbar connection+extra cable that way.

Oh, and Stanley knife here for cutting, works fine.

[Richard77]

Yeah looks like you are a bit further along and have a better skillset than me though!

I was glad to see your thread pop up and have been keeping an eye on how you are going about it.

It seems a bit of of a minefield with fake/poor quality cables, etc so always good to get an opinion from someone who has previously ordered through a certain company.

I think I am going to end up going the bus bar route and stick with 35mm² everywhere as the original leads that came with the batteries were 35mm² so they must be ok (I hope!).

Didn't particular like the style of some of the bus bar boxes though, they looked a bit exposed and not fully concealed.

Getting there though... Good luck mate.

[Richard77]

Edit: actually, i think I'll be able to simply fit 2 of the 25mm battery cables with M8 lugs straight into the Keto battery disconnector, saves the busbar connection+extra cable that way.

Oh, and Stanley knife here for cutting, works fine.

I wanted to bypass the bus bar and put both 35mm² cables from the batteries straight into the disconnect switch but the cables for the batteries have M8 fitting on and the keto 1 and nh1 mersen fused disconnect switches I was looking at both had M10 connections.

Didn't want to butcher the ends of the original cables to get them to fit. But I suppose I could just put different lugs on them?

I think it's ok to do that... As long as both lugs are secured tightly.

[pudding]

Ah, think I've got the smaller nh00 keto, which has m8 bolts&lugs. Did your batteries come with the cables? Like your say, shame to butcher them, but it'll make it a simpler install and saves cables/busbar & extra connections.

[Richard77]

Ah, think I've got the smaller nh00 keto, which has m8 bolts&lugs. Did your batteries come with the cables? Like your say, shame to butcher them, but it'll make it a simpler install and saves cables/busbar & extra connections.

Yeah I ordered 2x 15kwh cases from Colin on here.

Came with 2 lots of 35mm² cables with the snap on connector (unsure proper name for it) to go on the power terminals on the batteries. It was just annoying that the batteries only had 1 positive and 1 negative terminal on each battery, otherwise it would have been a bit more straightforward.

[Stinsy]

Yeah looks like you are a bit further along and have a better skillset than me though!

I was glad to see your thread pop up and have been keeping an eye on how you are going about it.

It seems a bit of of a minefield with fake/poor quality cables, etc so always good to get an opinion from someone who has previously ordered through a certain company.

I think I am going to end up going the bus bar route and stick with 35mm² everywhere as the original leads that came with the batteries were 35mm² so they must be ok (I hope!).

Didn't particular like the style of some of the bus bar boxes though, they looked a bit exposed and not fully concealed.

Getting there though... Good luck mate.

IP1X is drummed into sparks these days (basically nothing bigger than 1mm can get in contact with a live part). And all enclosures requiring a tool to open. Stuffing glands and Wiska boxes are the main way to achieve this. However many equipment manufacturers don’t seem to have gotten the memo.

While electric shock isn’t a risk with 48V, an accidental short would be very dramatic indeed.