Designing a Better Battery Cable

This photo of Springfield's Offgrid Battery

Designing a better off-grid Battery Cable

The pre-manufactured cables are all cut one-size fits-all (basically), which leads to critical problems.




First, Let's do some quick Battery Maintenance.

When it is opportune, checking specific gravity within the battery cells is a great way to see the true health of a battery.

Hydrometer a must for battery maintenance


At times a few drops of the battery acid may spill.

Do not under-estimate Battery Acid.

Battery acid spill

Neutralize any spills with plenty of Baking Soda

Battery Acid Neutralizer



Baking Soda is acid-neutralizer

Baking Soda NeutralizerKeep a box of Baking Soda near each Battery-Bank whenever possible.




Tip #2
Design a Better Battery Cable

Anyone having to check the specific gravity of each cell in each battery, or adding distilled water or sulphuric acid to each cell in each battery, has encountered the tangled web the corporate cable creates.

Cables are strewn seemingly everywhere no matter how well you try to loom them.

The mess of cables causes confusion, is a proponent of potential accidents, causes phantom energy loss due to unnecessary length/distance, and simply looks bad.




Springfield Offgrid Batteries and battery terminals

In contrast, notice the custom-cut cables in these photos. The connections to the cables are direct, easy to identify, inspect, and easy to work around.

Springfield battery terminals




As already stated, the improvement of replacing conventional Battery Connectors with Brass connectors solved corrosion issues. However, there are other common problematic issues intrinsic with contact of two metals and their long-term placement. Creating a better Battery Cable ought to follow suit.

Tailor-cut cable lengths allow for reduced costs in cabling; tailor-cut battery cables allow for reduced phantom energy loss and allows for a safer, more predictable work space.


So if you must use corporate cabling, chop it down to size and let's move on.




The Complexities of Series Connections within a Bank of Batteries

Pertaining to a solitary 12v battery, there is little to consider since it requires no series or parallel connections.

Cells intrinsic in the solitary 12v battery are all equal dimensions, a uniformity which can be equalized more-so than two 6 volt or six 2 volt batteries in series via cabling.

However if the same 12v battery were comprised with two 6 volt or six 2 volt batteries, long-term consideration of the quality and placement of the series connection cables are a variable worthy of prioritization.

Consider the ill-effect where each cable that connects from one battery to the next are all different thicknesses and lengths, what would be the effect?

Both will become vulnerable to either a short-circuit and energy-loss.

Direct cable connections from one terminal to the next allows for quicker transference of power with the least amount of heat loss (resistance).

Can we make the connections even better using tailored lengths of cabling?

Due to excess cable length, problems are created just as the detrimental effect of utilizing different sizes of cabling (whether it be at the battery bank or the distance from the battery bank to the end-user device, hub, or appliance).

INTERMISSION

Part Two

See a sudden problem with the performance of your batteries?

Remove all power source(s) and loads as soon as practical.

This video was inadvertently cut short (you didn't miss anything).

Note that one of the batteries tested within the video showed only 4 volts.

4 volts for a 6 volt battery is a very bad battery and must be quarantined from the bank of remaining batteries or the fault will affect the others adversely as well.

The fact that this is/was a 48 volt battery bank compounds problems since all eight batteries are necessary to equate to 48 volt. Due to the elimination of the solitary manufacturing defective pile of crack battery, the bank can only be either shut down pending the arrival of the replacement battery, or the 48 volt battery bank can be converted into a lesser voltage and used still.

In the next video, you will see this bank of batteries become a 12 volt battery bank, and observe the quick method to do so.

Click next for Photo examples and a more in-depth discourse pertaining to improving your Battery Cabling

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