Comments on: 2/0 Welding cable for the EV battery pack http://www.file037.com/ev/2009/09/18/20-welding-cable-for-the-ev-battery-pack/ An electric car conversion Fri, 05 Feb 2010 02:56:42 +0000 http://wordpress.org/?v=2.9.2 hourly 1 By: voltswagen http://www.file037.com/ev/2009/09/18/20-welding-cable-for-the-ev-battery-pack/comment-page-1/#comment-6 voltswagen Sat, 07 Nov 2009 22:01:35 +0000 http://file037.com/ev/?p=30#comment-6 Thanks John, I actually just read some information about the 1000 amp Zilla controllers use 4/0 cable. So, I think my 2/0 is overkill with my system. But, room to grow a bit if needed it looks. Also, I think the longest cable run will be from front (battery pack) to rear (controller and motor)... so maybe 7 feet. The rest I will try to keep short. Thanks John,
I actually just read some information about the 1000 amp Zilla controllers use 4/0 cable. So, I think my 2/0 is overkill with my system. But, room to grow a bit if needed it looks.

Also, I think the longest cable run will be from front (battery pack) to rear (controller and motor)… so maybe 7 feet. The rest I will try to keep short.

]]> By: John_G http://www.file037.com/ev/2009/09/18/20-welding-cable-for-the-ev-battery-pack/comment-page-1/#comment-5 John_G Sat, 07 Nov 2009 18:14:54 +0000 http://file037.com/ev/?p=30#comment-5 The diameter of the cable is determined by the amperage of the system and not by the voltage. Voltage determines the type and thickness of insulation you need. *Most* welding cable is 600V DC rated, but it's printed on the insulation jacket, so just check. "Safe" voltage is about 50% of rated for most applications where cable movement is possible due to the capacity to rub and chaffe. Cable is not amerage rated because the resistivity of the cable increases with length, cable is rated in ohms per foot (or meter). The longer the cable run, the larger the cable musst be to avoid excessive voltage drop. Same with amperage, the greater the amperage, the larger the cable must be. All that being said, there is nothing readily available, lower in resistance in terms of conneections, than flattened copper pipe. One main goal should be to reduce the cable lengths when ever and where ever possible. The diameter of the cable is determined by the amperage of the system and not by the voltage. Voltage determines the type and thickness of insulation you need. *Most* welding cable is 600V DC rated, but it’s printed on the insulation jacket, so just check. “Safe” voltage is about 50% of rated for most applications where cable movement is possible due to the capacity to rub and chaffe.

Cable is not amerage rated because the resistivity of the cable increases with length, cable is rated in ohms per foot (or meter). The longer the cable run, the larger the cable musst be to avoid excessive voltage drop. Same with amperage, the greater the amperage, the larger the cable must be.

All that being said, there is nothing readily available, lower in resistance in terms of conneections, than flattened copper pipe. One main goal should be to reduce the cable lengths when ever and where ever possible.

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