[EVDL List]

I just checked on the price of 2/0 AWG marine battery cable at my
local marine equipment shop and they are charging $7.?? a foot.
The stuff that they sell is made for the marine environment and is tin
plated or something to resist corrosion. I figure I don't need this
feature and hoped that there was a cheaper option.
What is a reasonable price for the 2/0 cable?
Where is a good place if I decide to order it?


Cheers,
--
Tehben
'90 Toyota 4x4 Pickup
'hElix EV'
Website: www.helixev.com
evalbum: http://www.austinev.org/evalbum/1225

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[EVDL List]

It's in the $2 range here:

https://weldingsupply.securesites.com/cgi-bin/einstein.pl?Next::1:UNDEF:OR:A2::PA

Also, local welding supply stores, and tractor supply have it on
spools. Maybe even HomeDepot/Lowes.

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try welders cable it is great for ev applications
----- Original Message -----
From: Tehben Dean<mailto:xxx@xxx.xxx>
To: EV mail list<mailto:xxx@xxx.xxx.edu>
Sent: Monday, August 27, 2007 7:10 PM
Subject: [EVDL] Battery Cable Price


I just checked on the price of 2/0 AWG marine battery cable at my
local marine equipment shop and they are charging $7.?? a foot.
The stuff that they sell is made for the marine environment and is tin
plated or something to resist corrosion. I figure I don't need this
feature and hoped that there was a cheaper option.
What is a reasonable price for the 2/0 cable?
Where is a good place if I decide to order it?


Cheers,
--
Tehben
'90 Toyota 4x4 Pickup
'hElix EV'
Website: www.helixev.com<http://www.helixev.com/>
evalbum: http://www.austinev.org/evalbum/1225<http://www.austinev.org/evalbum/1225>

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[EVDL List]

You will find 4AWG 2058 strands tinned OFC cable at 1,35$ here:

http://stores.ebay.fr/KnuKonceptz-com_Power-Wire_W0QQcolZ2QQdirZQ2d1QQfsubZ3QQftidZ2QQtZkm

They have other sizes also though more expensive ($3.25 for high quality
1/0)

i'm very happy with other the pond service and product so from USA it should
be even best :^)

regards,
Philippe



2007/8/28, FRED JEANETTE MERTENS <xxx@xxx.xxx>:
>
> try welders cable it is great for ev applications
> ----- Original Message -----
> From: Tehben Dean<mailto:xxx@xxx.xxx>
> To: EV mail list<mailto:xxx@xxx.xxx.edu>
> Sent: Monday, August 27, 2007 7:10 PM
> Subject: [EVDL] Battery Cable Price
>
>
> I just checked on the price of 2/0 AWG marine battery cable at my
> local marine equipment shop and they are charging $7.?? a foot.
> The stuff that they sell is made for the marine environment and is tin
> plated or something to resist corrosion. I figure I don't need this
> feature and hoped that there was a cheaper option.
> What is a reasonable price for the 2/0 cable?
> Where is a good place if I decide to order it?
>
>
> Cheers,
> --
> Tehben
> '90 Toyota 4x4 Pickup
> 'hElix EV'
> Website: www.helixev.com<http://www.helixev.com/>
> evalbum: http://www.austinev.org/evalbum/1225<
> http://www.austinev.org/evalbum/1225>
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev<
> http://lists.sjsu.edu/mailman/listinfo/ev>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>
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If you're looking for 4/0 cable, (96 strand I believe), I can supply 11'6" lengths for $30, two for $50, shipping included. They're salvaged from '80's BMW's, routed inside the car connecting the trunk battery to the firewall. If the ends are too corroded for ICE tweakers, they go to EV use.
The OD of the copper is .415", molded on insulation and stiffer than welding cable.
Several listees have 'em. I find a few a month, so quantities are limited.

-Harry Houck, Fresno, CA
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$7.xx a foot is cheaper than "evparts.com"

http://www.evparts.com/shopping/search.php?concatenation=AND&case_sensitive=0&Sear ch=search&stringtsf=2%2F0

$8.85 US for black; shipping not included.
Its good cable (I bought some a while back for a little less than $6 a
foot, which I thought was high then.)

Whats going on?
I've heard China this, China that....
Are Chinese purchases really driving these prices up?


Ed Cooley





"vehiculeselectriques.free.fr" <xxx@xxx.xxx>
Sent by: xxx@xxx.xxx.edu
08/28/2007 09:50
Please respond to
Electric Vehicle Discussion List <xxx@xxx.xxx.edu>


To
"Electric Vehicle Discussion List" <xxx@xxx.xxx.edu>
cc

Subject
Re: [EVDL] Battery Cable Price






You will find 4AWG 2058 strands tinned OFC cable at 1,35$ here:

http://stores.ebay.fr/KnuKonceptz-com_Power-Wire_W0QQcolZ2QQdirZQ2d1QQfsubZ3QQftidZ2QQtZkm


They have other sizes also though more expensive ($3.25 for high quality
1/0)

i'm very happy with other the pond service and product so from USA it
should
be even best :^)

regards,
Philippe



2007/8/28, FRED JEANETTE MERTENS <xxx@xxx.xxx>:
>
> try welders cable it is great for ev applications
> ----- Original Message -----
> From: Tehben Dean<mailto:xxx@xxx.xxx>
> To: EV mail list<mailto:xxx@xxx.xxx.edu>
> Sent: Monday, August 27, 2007 7:10 PM
> Subject: [EVDL] Battery Cable Price
>
>
> I just checked on the price of 2/0 AWG marine battery cable at my
> local marine equipment shop and they are charging $7.?? a foot.
> The stuff that they sell is made for the marine environment and is tin
> plated or something to resist corrosion. I figure I don't need this
> feature and hoped that there was a cheaper option.
> What is a reasonable price for the 2/0 cable?
> Where is a good place if I decide to order it?
>
>
> Cheers,
> --
> Tehben
> '90 Toyota 4x4 Pickup
> 'hElix EV'
> Website: www.helixev.com<http://www.helixev.com/>
> evalbum: http://www.austinev.org/evalbum/1225<
> http://www.austinev.org/evalbum/1225>
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev<
> http://lists.sjsu.edu/mailman/listinfo/ev>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>
_______________________________________________
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[EVDL List]

It seems like this cable is meant for 12V vehicle use. It might not be a
problem, but be sure that the insulation is rated at least as high as your
pack voltage.

Phil


>From: "vehiculeselectriques.free.fr" <xxx@xxx.xxx>
>Reply-To: Electric Vehicle Discussion List <xxx@xxx.xxx.edu>
>To: "Electric Vehicle Discussion List" <xxx@xxx.xxx.edu>
>Subject: Re: [EVDL] Battery Cable Price
>Date: Tue, 28 Aug 2007 15:50:38 +0200
>
>You will find 4AWG 2058 strands tinned OFC cable at 1,35$ here:
>
>http://stores.ebay.fr/KnuKonceptz-com_Power-Wire_W0QQcolZ2QQdirZQ2d1QQfsubZ3QQftidZ2QQtZkm
>
>They have other sizes also though more expensive ($3.25 for high quality
>1/0)
>
>i'm very happy with other the pond service and product so from USA it
>should
>be even best :^)
>
>regards,
>Philippe
>
>
>
>2007/8/28, FRED JEANETTE MERTENS <xxx@xxx.xxx>:
> >
> > try welders cable it is great for ev applications
> > ----- Original Message -----
> > From: Tehben Dean<mailto:xxx@xxx.xxx>
> > To: EV mail list<mailto:xxx@xxx.xxx.edu>
> > Sent: Monday, August 27, 2007 7:10 PM
> > Subject: [EVDL] Battery Cable Price
> >
> >
> > I just checked on the price of 2/0 AWG marine battery cable at my
> > local marine equipment shop and they are charging $7.?? a foot.
> > The stuff that they sell is made for the marine environment and is tin
> > plated or something to resist corrosion. I figure I don't need this
> > feature and hoped that there was a cheaper option.
> > What is a reasonable price for the 2/0 cable?
> > Where is a good place if I decide to order it?
> >
> >
> > Cheers,
> > --
> > Tehben
> > '90 Toyota 4x4 Pickup
> > 'hElix EV'
> > Website: www.helixev.com<http://www.helixev.com/>
> > evalbum: http://www.austinev.org/evalbum/1225<
> > http://www.austinev.org/evalbum/1225>
> >
> > _______________________________________________
> > For subscription options, see
> > http://lists.sjsu.edu/mailman/listinfo/ev<
> > http://lists.sjsu.edu/mailman/listinfo/ev>
> > _______________________________________________
> > For subscription options, see
> > http://lists.sjsu.edu/mailman/listinfo/ev
> >
>_______________________________________________
>For subscription options, see
>http://lists.sjsu.edu/mailman/listinfo/ev

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[EVDL List]

[EVDL List]

[quote]Tehben Dean wrote:

> Before I actually purchase, would there be any benefit to
> using #2 if I found deal?

I suppose that depends on the cost of the #2 terminals you would need vs
the #4 you could use. A deal on the cable could actually be offset by
the difference in terminal cost!

The #2 will run a bit cooler than the #4, but that's really the only
benefit.

Quoted below is a gem from Bill Dube explaining the wire size issue more
clearly.

Cheers,

Roger.


> -----Original Message-----
> From: xxx@xxx.xxx [mailto:xxx@xxx.xxx]
> Sent: Tuesday, June 04, 2002 6:11 AM
> To: xxx@xxx.xxx.edu
> Subject: Re: cable amp ratings - The Facts
>
> >Arthur Matteson wrote:
> >> So do the wire rules not apply to cars?
> >
> >Actually they still apply, but use the degrees C rise for cross
> >section, and current flow equation. Then take into account how
> >fast you can disipate the heat away from the conductor bundle.
> >>From that you then can figure out the minimum wire size needed
> >then double to quadruple it to handle individual strand breakage
> >and unexpected conditions. No, I don't know the actual equations
> >off the top of my head and those books are packed.
>
> It is all about heat transfer.
>
> First, you determine how hot the insulation can get
> before it is damaged.
> This can be 60 C (or less) for thermoplastic (like vinyl)
> insulation. (An example is the pretty stereo wire that
> turns to goo when the wires get even slightly warm.) Some
> of the Silicone or Teflon insulated wiring can take as
> much as 200 C without a problem. It is just as pretty as
> stereo wire, but costs quite a bit more. Welding wire is
> typically 75 C or 90 C insulation.
>
> There are two operating regimes, intermittent and
> continuous. The continuous rating is what you will find
> in the National Electrical Code, Section 70, Tables 310-16
> through 310-19. For DC use, the formula is
>
> TC-TA
> I = Squareroot( ----------------)
> RDC * RCA
>
> where
> TC = conductor temperature, C (what the insulation will
> withstand)
> TA = The ambient temperature, C
> RDC = The DC resistance of the conductor at TC
> RCA = Effective thermal resistance between the
> conductor and it's surroundings. (Typically
> 450 to 650 C-cm/watt)
>
> 2/0 welding cable works out to be 200 amps continuous.
>
> The intermittent rating is what seems to confuse most
> folks. From Beeman's "Industrial Power Systems Handbook"
> page 183, we have the formula for copper conductors:
>
> 1 (T2 + 234)
> t = ----------------- log10 (---------------)
> I (T1 + 234)
> (33) * (-------) ^2
> CM
>
> where
> t = time, seconds
> I = RMS current, amperes
> CM = Conductor cross section, circular mils
> T1 = Initial conductor current, Celsius
> T2 = Final conductor temperature, Celsius
>
> Eye-balled from the chart on page 184,
>
> 2/0, 75 C rise,
>
> RMS Amps t, seconds
> 8,000 1
> 3,300 5
> 2,200 10
> 1,400 30
> 900 60
>
> 30 second duration for 75 C rise (This would be for a "peppy" EV)
>
> Gauge RMS Amps
> 10 120
> 8 170
> 6 280
> 4 530
> 2 700
> 1 800
> 1/0 1100
> 2/0 1300
> 3/0 1700
> 4/0 2100
>
> This formula assumes that all the heat is absorbed by
> the copper and none is transferred to the air. This is a
> pretty good assumption for short time intermittent loads
> like this. This assumed temperature rise (75 C) would be
> good for welding wire type insulation, but way off for goofy
> vinyl insulation.
>
> You can see that there are no simple answers.
>
> The keys are the "cruising" amperage and the duration
> and magnitude of the intermittent amperage. If you have a
> very light EV and a huge controller, the duration of maximum
> current will be very low, perhaps 15 seconds or so.
> A heavy EV with a smallish controller will have max current
> durations of perhaps 10 minutes or more.
>
> The KillaCycle has a max motor current of 1400 amps
> that lasts about 10 seconds. I use #2/0, but #1/0 welding
> cable would more than thick enough for the motor leads.
> #1 might get a little warm.
>
> Since the battery current is essentially a ramp from
> zero with a peak of 1400 amps, the RMS current during that
> time is 808 amps. (To find the RMS value of a ramp, divide
> by the square root of 3.) This mean that the minimum wire
> size would be about #3 (from the chart.) I use two #6 flat
> copper braids in parallel for battery interconnects and they
> work just fine.
>
> These calculations will give you the minimum wire
> diameter based on allowable insulation temperature. It turns
> out that for acceleration performance, like on the drag strip,
> the optimal wire diameter typically comes out a little smaller!
>
> I haven't done the calculation for optimal range, but
> it probably close to the NEC size for the cruise current.
> You still have to do the temperature-limit calculation above
> for the max current to make sure that you don't damage the
> wire during max throttle accelerations.
>
> _ /| Bill "Wisenheimer" Dube'
> \'o.O' <xxx@xxx.xxx>
> =(___)=
> U
> Check out the bike -> http://www.KillaCycle.com

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