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brulaz's avatar
brulaz
Explorer
Jun 30, 2016

Cable Lugs or 1/0 cable

Originally setup to just run a small coffee grinder, we're now trying to pull 70ADC from the batteries to run an induction hotplate.

For some reason, these things always seem to get out of hand ... :R

Anyway it's time to upgrade the cables to and from the 1000W inverter. (And maybe later a 2000W inverter will happen.)
Was thinking about 1/0 cable, about 8-12' depending upon routing.

The old cables used simple tinned copper lugs with a V-crimp made with a "Heavy-Duty Hammer Crimper" from Del-City. And lots of electrical anti-corrosion paste, also from Del-City.

Would similar V-crimped lugs be adequate for the new 1/0 cables? Or do they add too much resistance at high loads? The old cables do seem to have more voltage drop than I predicted based solely on the cable length and size.

Alternative lugs might be the Fusion solder lugs. Not cheap, but I only need 4 and still cheaper than a $200-300 crimping tool.

And then I hear of people using thick walled copper pipe? And solder?

I would rather cut and lug the cables myself as I'm not exactly sure of their routing.

Thanks.

12 Replies

  • Forty bucks will get you a pentagon or octagon die hydraulic crimper on eBray. You'll never see a high amperage HV transmission line made with a dimple crimp. Medium voltage 250 MCM Al line has eight strands. A very different environment.

    Go with the "eleven die" eBray crimper. Most offer free shipping and the pump lies on the ground giving you one free hand to retain the conductor.

    Hard copper pipe is not nearly as pure as electrolytic copper. And heavy duty grade lugs have three times as thick Sn (tin) plating as cheap thin lugs. Cast copper lugs are by far the best bet. That and triple-wall heat shrink cable tubing. Anti-rotation style CAST lugs always gave me the best service. Go to Delcity.net and start searching. BTW, for some reason one size larger lugs fit much better when using AWG rather than SAE grade wire. So buy 2/0 lugs for 1/0 AWG cable.


  • Many years ago I used these. Easy peasy, no corrosion, no heat. That is 4/0 cable. Ace Hardware I believe- just attach with an Allen wrench. Of course I was given dire warnings about Al/Cu connections and the things coming loose. Both turned out to be false.

    I don't sweat connections and wire much anymore running 48vdc.

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