Forum Discussion

Empty_Nest__Soo's avatar
Mar 18, 2015

Trimetric shunt/wire size question

I’m planning the install of a Trimetric battery monitor and I have a question about mounting/wiring the shunt.

After studying my layout, I feel the simplest way to mount the shunt is to make a bracket to both mount i t and attach one of its terminals to the negative terminal of the battery bank. I would then connect the negative battery lead to the other terminal on the shunt.

The main battery cables appear to be either 3/0 or 4/0 AWG. If I make a bracket/conductor, it will only be about 4 or 5 inches long. Plugging this length and 200 amps at 14 volts into a wire size calculator, I get some absurdly small wire gauge.

For material, I plan to use some 50-year-old copper pipe that was removed from our house during remodeling 10 years ago. Carefully measuring the flattened pipe, I come up with a cross sectional area slightly greater than 1/0 solid copper wire. If I were to sandwich 2 pieces together, it would be a hair more in cross sectional area than 4/0 solid copper.

If I were to make the bracket with one thickness of flattened copper pipe, with a cross sectional area equal to 1/0 wire, would that be adequate for 4 or 5 inches in this application? Or should I go 2 thicknesses, equal to 4/0?

For reference: I have 4 Group 27 12-volt batteries in parallel and a 2000 watt inverter that will charge at a maximum of 100 amps. When batteries need replacement, I expect to go with 4 6-volt golf cart batteries.

Wayne
  • CA Traveler - Your photo and another that I found on-line were part of the inspiration for the solution I propose to use. I also plan to place a copper tab on the other end of the shunt so that I can easily attach the black lead of my portable charger to that and, I hope, keep a running tab of the SOC.

    The copper pipe I plan to use as raw material is about 50 years old, and has a wall thickness about double that of the new pipe that I have.

    Grizzzman - I'm not worried so much about voltage drop. I'm more worried about the bracket getting hot if it's cross sectional area is too small.

    Wayne
  • Go with double thickness, it is not that expensive!

    I made my own battery ends for the 000 welding cable that I installed for my 1,500 watt inverter and E-Meter - a early version of the Tri-Metric.

    I also broke all the rules and used #18 gauge thermostat wire, not the recommended twisted pair wire. I did install 2 fuses, and all that. As I recall (going back to 1999 when I installed the e-meter) it has 2 each +12 wires, and 2 wires to the shunt (that are ground wires) and a ground wire for conducting power to the meter. Instructions say to connect one fuse first, then the second one. I guess it matters, but each time that I connected my battery, it all got connected at the same time.

    It has worked great for many years. And many boondocking nights. I have gone to -120 amp hours and my 415 rated watt solar system can recharge that in one day. Any more than -120 AH, and I will run the generator in the morning to get the most amps per hour into the battery with my Trace 1500 watt inverter/charger rated at 70 amps output.

    I have 4 golf cart batteries, rated at 440 AH total.

    In truth, you could barely measure the voltage drop across 6" of copper wire. So it really does not matter. But materials are almost free, and time is hardly anything too.

    I made my copper ends with 1/2" soft copper ACR tubing (I have lots sitting around) and flatten one end in a vice, then fold back about 1.5" and drill a 3/8" hole in it. Then had about 1" left at 1/2" diameter to insert the wire, and crimp it in the vice. None have failed in the 15 years that they have been in my motorhome.

    Good luck with your projects!

    Fred.
  • BTW There is different wall thickness pipe for different maximum pressure. Unlikely to make any difference for that short distance.
  • You dont trust the voltage drop calculator?(and i have seen this done with a shunt). You dont have any distance to speak of. If it is strong enough,Go for it. I dont think .0079 voltage drop at 200 amps is gonna break the bank.