Hello Roger, Use a heavy duty copper battery clamp which has a crimp type barrel. Strip the insulation off the 2/0 cable about 1/8 inch longer than the round part of the barrel. Hold the cable in bench vice that has insulated jaws or someone holding the cable. Set the battery clamp in the crimper and push the battery clamp onto the cable end until the insulation butts against the battery clamp. The extra 1/8 of strip cable will press into the table end of the barrel.
If the barrel is a single length, crimp about 1/8 of a inch from the wire insert in. If the barrel is a double crimp type, crimp the wire insert in first and than crimp the post end second. If the post end is crimp first, the cable could move out which is cause by taper. Before I install the other battery clamp on the same link, I slide on heavy duty heat shrink that has a sealant in it. I use one red and one black heat shrink. Next, I coat the battery clamps with a acid proof rubber coating which is a red color for the positive and black color for the negative. Do not coat the contact surfaces that touches the battery post. The acid proof rubber coating is some of the same stuff that is use to insulated tool handles with. After the coating dries, than I install the heat shrink over the barrels. I also install the pretreated red and black battery post anti-corrosion on the post under the battery clamps. Torque the battery clamp bolt to 60 inch pounds. If the post has a top stud, I install a stainless steel washer, lock washer and nut and torque it to 60 inch lbs which puts extra internal pressure to the battery clamp. After driving for the first 5 miles, re-torque the battery clamp again, it is normal for it to loss about 5 inch pounds, because the surface contacts melt back a little. I use this method on my last battery pack, in install on Sept 4, 2009. They now have 3072 cycles on them and only water them every 6 months. There is no corrosion because I use a fiber glass epoxy coated battery box. When I turn of the ignition switch, the batteries are disconnected from the main contactor and motor controller and also from the battery charger. I found that the PFC battery charger capacitor bank was holding a charge at the battery even after the battery charger was off. When I remove a link from a battery, it cause a spark. Disconnecting the battery from the battery charger using a 2-pole DC contactor solve this problem and also reduce the corrosion. Roland ----- Original Message ----- From: Roger Daisley via EV<mailto:[email protected]> To: [email protected]<mailto:[email protected]> Sent: Friday, May 09, 2014 7:11 PM Subject: [EVDL] Battery post - Best Practice I am going to give the Costco 6v golf cart Batteries a try. I just hauled home 18 of them. (56 lbs, ea.) My previous battery set has the L-foot terminals, while the Costco batteries have the post, with 5/16 screw. My controller draws about 550 amps, max. (Usually, under one minute duration.) What would be the best practice to hook up 2/0 cabling, with lug ends? Roger Daisley Pullman, WA -------------- next part -------------- An HTML attachment was scrubbed... URL: <http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20140509/8767a258/attachment.htm<http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20140509/8767a258/attachment.htm>> -------------- next part -------------- A non-text attachment was scrubbed... Name: not available Type: image/gif Size: 70 bytes Desc: not available URL: <http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20140509/8767a258/attachment.gif<http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20140509/8767a258/attachment.gif>> _______________________________________________ UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub<http://www.evdl.org/help/index.html#usub> http://lists.evdl.org/listinfo.cgi/ev-evdl.org<http://lists.evdl.org/listinfo.cgi/ev-evdl.org> For EV drag racing discussion, please use NEDRA (http://groups.yahoo.com/group/NEDRA<http://groups.yahoo.com/group/NEDRA>) -------------- next part -------------- An HTML attachment was scrubbed... URL: <http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20140509/2c61a68a/attachment.htm> _______________________________________________ UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub http://lists.evdl.org/listinfo.cgi/ev-evdl.org For EV drag racing discussion, please use NEDRA (http://groups.yahoo.com/group/NEDRA)
