What gauge of wire should I use?

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jdh2550_1
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What gauge of wire should I use?

I want to relocate one of my XM-2000 batteries (just turn it through 90 degrees) and I need to make a longer cable.

What gauge wire should I use? The system draws up to 60 amps (per usatracy and PJD). Where's a good place to buy wire, lugs and crimpers?

Thanks!

andrew
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Re: What gauge of wire should I use?

http://www.evsource.com is where I got all the wire and lugs for my project.

The max current for the XM-2000 has not been established, as I don't see any actual tests done, and the xtreme specs may not be accurate at all.

6 guage should be overkill, but if its cheap enough and small enough to fit in there than I'd go with it.

I think most hardware stores carry up to 6 guage lugs, but I don't know if they'll have the wire. You may also want heat shrink.

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jdh2550_1
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Re: What gauge of wire should I use?

Does it need to be solid copper or is 6 gauge multi-stranded OK? I can buy 6 gauge multi-stranded at Home Depot...

Thanks,
John H.
Blue XM-2000
Ann Arbor, MI

John H. Founder of Current Motor Company - opinions on this site belong to me; not to my employer
Remember: " 'lectric for local. diesel for distance" - JTH, Amp Bros || "No Gas.

andrew
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Re: What gauge of wire should I use?

The multi-stranded is better both for ease of installation, and current load capability.

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mf70
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Re: What gauge of wire should I use?

"Battery Warehouse" type stores generally have a fab bench to make cables. They'll have all possible gages of wire, as well as terminals. Take one of the existing cables in and they'll match them.

reikiman
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Re: What gauge of wire should I use?

Another option is West Marine. They have wire at gauges up to 00 (welding wire) with lugs to match and they can build cables (or so the local store told me). Some boats have significant electrical wiring in them including electrical drive trains, so West Marine is actually an interesting source for parts. A bit overpriced usually, unfortunately. But I think it's an interesting place to go because they'll have selected parts based on how well they survive on the ocean, which means they're suitable for taking out in the rain and other weather.

- David Herron, http://davidherron.com/

andrew
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Re: What gauge of wire should I use?

From http://www.powerstream.com/Wire_Size.htm 10 gauge wire is listed at about 1 ohm per 1000 feet. If the xm-2000 had 10 feet of high-power wiring than this would result in:

1 ohm/100 * 60 amps (not established yet) = .6 v drop * 60 amps = 36 watts or 3.6 watts per foot of heat to dissipate. I think it'll be fine if you replace the batteries with li-ion for longer run times.

My motorcycle wire gets kind of warm. Its 2 gauge and I pull a max of about 600 amps:

.1563 ohms/55.55 (1000/18ft of wire) = .0028 ohms * 600 * 600 = 1008 watts / 18 ft of wire = 56 watts per foot.

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Avatar taken from http://www.electricmotorbike.org/
Anyone got one they want to sell?
My KZ750 Project: here

[url=/forum-topic/motorcycles-and-large-scooters/587-my-kz750-electric-motorcycle-project]KZ750 Motorcycle Conversion[/url]
[url=/forum-topic/motorcycles-and-large-scooters/588-fixing-my-chinese-scooter]900 watt scooter[/url]
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PJD
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Re: What gauge of wire should I use?

Just so you know, I used 8-gauge on my e-max.

It draws up to about 90-100 amps and the wires don't get the least bit warm. So, at 60 amps, anything less than 8-gauge is probably just overkill, and at current copper prices, wasting money.

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