Empathy List Archives

DM

Duane Maher

Tue, Dec 7, 2004 2:12 AM

List,
I plan to add additional batteries, high output alternator, multistep
regulator and a battery monitor to my new boat. I have done this twice on my
previous American made sailboats.

In surveying my new Mariner 38 trawler electrical system, I have found battery
cables in the sizes of 95mm, 70mm and 35mm square. Not exactly the same sizes
as the American standard (2/0 - 68mm squared, 3/0 - 85mm squared and 4/0 - 107
mm squared). My question is where do I find the proper size lugs? I will need
to reterminate some of these cable runs. Do I go the next size up or next size
down and try to make it fit. This makes me a little uncomfortable. Any help
would be appreciated.

Duane Maher
Rosaleah
Mariner 38 Double Cabin #22

List, I plan to add additional batteries, high output alternator, multistep regulator and a battery monitor to my new boat. I have done this twice on my previous American made sailboats. In surveying my new Mariner 38 trawler electrical system, I have found battery cables in the sizes of 95mm, 70mm and 35mm square. Not exactly the same sizes as the American standard (2/0 - 68mm squared, 3/0 - 85mm squared and 4/0 - 107 mm squared). My question is where do I find the proper size lugs? I will need to reterminate some of these cable runs. Do I go the next size up or next size down and try to make it fit. This makes me a little uncomfortable. Any help would be appreciated. Duane Maher Rosaleah Mariner 38 Double Cabin #22

E

elnav@uniserve.com

Tue, Dec 7, 2004 6:32 AM

Quoting Duane Maher duane@maher.name:

My question is where do I find the proper size lugs? I will
need to reterminate some of these cable runs. Do I go the next size up or next
size down and try to make it fit. This makes me a little uncomfortable. Any

help would be appreciated.

REPLY
Much depends on whattype crimp tool you will be using.
A "Box" type crimper ( Burndy and T&B style) which creates a square box shaped
impression into the round lug requires more closely matched wires and crimps.

Ancor sells a crimp tool which has an adjustable die and a single round nosed
pin impression. This is my preference since it does allow yo uto adjust for a
mismatch of lugs and wires.
Another solution is to add extra strands to fil the space inside the crimp
barrel befoer crimping down.

Since a pull test is not practical on this size cable connection you have to
rely on past experience and judgement.
Having done two previous boats I suspect you do havethe requisite experience to
judge if your crimp is sound.

Trying to stuff a cable into a too small crimp barrel is more problematic.
I would not recommend that approach.

Arild

Quoting Duane Maher <duane@maher.name>: > My question is where do I find the proper size lugs? I will > need to reterminate some of these cable runs. Do I go the next size up or next > size down and try to make it fit. This makes me a little uncomfortable. Any help would be appreciated. REPLY Much depends on whattype crimp tool you will be using. A "Box" type crimper ( Burndy and T&B style) which creates a square box shaped impression into the round lug requires more closely matched wires and crimps. Ancor sells a crimp tool which has an adjustable die and a single round nosed pin impression. This is my preference since it does allow yo uto adjust for a mismatch of lugs and wires. Another solution is to add extra strands to fil the space inside the crimp barrel befoer crimping down. Since a pull test is not practical on this size cable connection you have to rely on past experience and judgement. Having done two previous boats I suspect you do havethe requisite experience to judge if your crimp is sound. Trying to stuff a cable into a too small crimp barrel is more problematic. I would not recommend that approach. Arild

MR

Mark Richter

Wed, Dec 8, 2004 1:25 PM

Duane,
There are several series of terminal sizes, such that not all #2/0 terminals
have the same inside diameter. Those made for fine strand wire have a
slightly larger ID. If you find an electrical supply with a large
selection, it's likely you can find a terminal that is a snug fit for each
of your cables. If the nearest terminal is a BIT too small, you can cut a
FEW strands of the cable to make it fit. Most 12v battery cables are sized
for voltage drop, not ampacity, and the small discontinuity probably won't
matter. If in doubt, consult someone knowledgable about the specific case
in question..

Often, in cutting old cables for new terminals, I find corrosion such that
there is no reliable way to get a good connection of the new terminal. In
these cases, the cable should be replaced with new.

Mark Richter, Mark's Mobile Marine
Electrical Systems and general boat repair.
Ortona, FL (on the Okeechobee Waterway)
772-631-7408 Verizon cell
presently dock building

Duane, There are several series of terminal sizes, such that not all #2/0 terminals have the same inside diameter. Those made for fine strand wire have a slightly larger ID. If you find an electrical supply with a large selection, it's likely you can find a terminal that is a snug fit for each of your cables. If the nearest terminal is a BIT too small, you can cut a FEW strands of the cable to make it fit. Most 12v battery cables are sized for voltage drop, not ampacity, and the small discontinuity probably won't matter. If in doubt, consult someone knowledgable about the specific case in question.. Often, in cutting old cables for new terminals, I find corrosion such that there is no reliable way to get a good connection of the new terminal. In these cases, the cable should be replaced with new. Mark Richter, Mark's Mobile Marine Electrical Systems and general boat repair. Ortona, FL (on the Okeechobee Waterway) 772-631-7408 Verizon cell presently dock building

trawlers@lists.trawlering.com

Battery Cable Sizes