RE Lab Experiment #1; BATTERY CABLES; Preliminary Results [RE-wrenches]

[Drake Chamberlin - Electrical Energy]

<x-flowed>Hi Wrenches,

     Early results from the ACID TEST of various cables, which might 
be considered for battery connections, are now in.  All cables have 
been in solution for at least a week at this point.

CABLES TESTED:

2/0 AWG THW OR OIL RESISTANT I 600 V E70347 Made in Canada From Bob-O Schultz

2/0 ESSEX EXCELENE WELDING CABLE from Bob-O Schultz

4/0 COBRA WIRE & CABLE X-FLEX E163983 (UL) MTW OR THW OR AWM 600V, 
105 DEGREES C (TRACE CABLE) from Quicksilver Electrical

4/0 CAROL PRENE WELDING CABLE 600V from Quicksilver Electrical

4/0 CAROL SUPER VU-TRON TYPE W PORTABLE POWER CABLE RHH OR RHW 90 
DEGREES C DRY 75 DEGREES C WET 2000 V from Quicksilver Electrical

2/0 HYPALON DIESEL LOCOMOTIVE CABLE IEEE 383 --- CSA AWM 8A 90C 600V 
FTI TYPE USE OR RHH OR RHW FOR CT USE VW-I  A.I.W. CORP  from 
Electrical Energy

2/0 ESSEX THHN OR THWN 600V from Quicksilver Electrical

RESULTS:

     The only cable to show any visible signs of deterioration is the 
THHN / THWN.  The battery acid became dark and discolored within a 
day.  Well before the end of a week, the solution became so dark that 
the cable sheath within was difficult to see.
     The THHN / THWN sheath was taken out of the acid for examination. 
It appears to be losing mass, but is still in tact.  The sheath will 
go back into the solution.
     None of the other cable has shown any visible signs of 
deterioration.  The battery acid for the other samples have shown no 
signs of discoloration.

WHAT IS IMPLIED

     The implications, at this point, are that welding cable seems to 
hold up as well to acid as the cables that are presently approved for 
use in battery boxes.  The THHN / THWN cable, which is not approved, 
and is not particularly popular for use as battery interconnects, has 
the least suitable insulation of the cable sheaths tested.
     The cables will be allowed to soak for a longer period.  After 
this period, the cables will be subjected to testing with a mega ohm 
meter (Meggar) to determine if there is any loss of resistance to 
applied voltage.

REMARKS

     It is probable that the tested insulation has already been 
subjected to more acid contact than a cable in a battery compartment 
would be during its entire period of use.
     Many approved cables have pure copper conductors within the 
insulation.  The difference between the various cable is therefore 
mainly in the insulation.  Although stranding size may vary, finely 
stranded cable is approved for use in battery compartments, even 
though fine strands are more susceptible to deterioration.
     The insulation on THHN / THWN wire demonstrates a susceptibility 
to acid, and would probably be the least suitable for use in battery 
boxes.
     Coincidentally, yesterday we went on a site visit to an existing 
system.  The battery jumpers were made from type THHN cable.  They 
seemed to be in excellent shape.  The actual amount of acid contact 
with cables in battery boxes is likely to be small.
     The CAROL SUPER VU-TRON TYPE W PORTABLE POWER CABLE RHH OR RHW is 
a cable that has been accepted for use in battery compartments under 
current regulations.  However it has an extremely thick sheath and is 
very awkward to work with.  It is difficult to get two of these 
cables into 2" Schedule 80 PVC conduit.
     The experiment is not complete.  These findings, although 
preliminary, demonstrate that no catastrophic results occur when 
welding cable is exposed to battery acid.

Drake Chamberlin
Electrical Energy
(303)399-1025

Don Wallingford
Quicksilver Electrical
(303)833-4214



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