4/0 DC Wiring

Midwilshire · May 26, 2014, 07:04:49 PM

Looking for opinions on the type of 4/0 cable recommended for house battery to inverter connections. The web has mixed reviews of using welding cable for this purpose.

Also, is it fairly easy to use one of those $15 lug crimpers that one smacks with a hammer? Or, should I just order the cables pre-made?

Any other thoughts on making these connections?

Thanks in advance,

Mike

lvmci · May 26, 2014, 08:50:43 PM

Hi Mike, got mine at Interstate Battery with 2/O crimped, color coded, positive and negative cables for the battery compartment, made to order, and length with ad on 14 gauge tag to hook charger maintainers to the batteries, lvmci...

Dave5Cs · May 26, 2014, 09:09:54 PM

Mike my Magnum 4024 install instructions say for 12 volt use 4/AWG for 24 volt use 2 AWG. It says do not use welders cable. The stranding is not as good and carries less current. Any commercial battery shop or diesel repair can make cables or bring the cable and ends and they will clamp them on for you. also mentioned that you should make all cables as short as possible.

Dave

scanzel · May 27, 2014, 05:24:29 AM

Had all my cable made up at a local battery seller, red and black crimped and heat shrink ends. Trying to buy the cable, crimp end and then the crimper it was less cost to just let the battery shop make them. Keep all cables as short as possible and of equal length.

gumpy · May 27, 2014, 05:49:28 AM

I used 4/0 welding cable.

I made my own lugs using copper pipe and solder.

http://www.gumpydog.com/Bus/MC9_WIP/Electrical/Batteries/batteries.htm

sparkplug188 · May 27, 2014, 06:52:48 AM

Watch for scraps from commercial wiring jobs on Ebay and your local scrap recyclers. Often times you can fine 10' to 15' lengths of service entrance cable for scrap copper cost per pound. I replaced all of my battery, starter, and alternator wiring with 300 kcmil cable that cost half as much as new 4/0 cable.

Midwilshire · May 28, 2014, 10:24:54 AM

Thanks for all the helpful replies guys. Gumpy, how are your home made lugs holding up?

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Bob Gilbert · May 28, 2014, 10:32:47 AM

Did mine like Gumpy on issues after 10 years

luvrbus · May 28, 2014, 11:54:42 AM

I sure like the Fusion lugs from DelCity 4 to 6 bucks each best thing since sliced bread and stronger than the crimp on lugs

eagle19952 · May 28, 2014, 03:23:23 PM

These and the fusion types are my current choice....and I own a crimping tool...

gumpy · May 28, 2014, 03:43:07 PM

Quote from: Midwilshire on May 28, 2014, 10:24:54 AM
Thanks for all the helpful replies guys. Gumpy, how are your home made lugs holding up?

Not a single issue. I think it's been 10 years now.

One thing I did when I made them was to get flux down inside the pipe and cable before smashing it
and then when I soldered it, I stood it on end in the vice and filled the end solid with solder. Yes, it can wick up the cable a bit but really, cables that large
and that short don't have a lot of flex in them anyway, but there's enough flex left that they can be bent to the proper shape for installation. I also used
heavy duty heat shrink tubing on each end to seal the joint where the cable is slightly exposed.

Oonrahnjay · May 28, 2014, 04:03:27 PM

Quote from: gumpy on May 28, 2014, 03:43:07 PM... I also used heavy duty heat shrink tubing on each end to seal the joint where the cable is slightly exposed.

Probably one of the most important things that you did (IMO). Nice work.