Flexible Cables: Important Safety Issue [RE-wrenches]

[Ray Walters]

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Just to get this excellent topic back into the tech only realm, Let's talk 
strand count. I posted previously that I was using a 133 strand at 2/0 
battery cable that is SAE rated.
I see from my sources that welding cable has 1323 strands at 2/0.  Thats 
way too fine IMHO.
Some THHN 2/0 I just counted my self has only 19 strands. Obviously that is 
way too stiff.
What is the Cobra 2/0 strand count?
BTW, that THHN was just pulled out of an otherwise first class install 
because its resistance at the crimp connector was so high it was dropping 
10 volts on a 24 volt system. Other symptoms included bent battery 
terminals, batteries pushed out of alignment, and cracked insulation. This 
was a complete system failure (no usable power in or out) and THHN in the 
battery compartment was the culprit.
I'm sticking to the 133 strand stuff. I use a UL listed standard lug from 
DC wire that is identical to the Trace inverter cable lugs. I have 4 
different crimpers, but my current favorite is a handle style that was 
designed exclusively for the standard lugs (part#990065). I have pull 
tested this crimp (hitched it to my pickup, I was born in Oklahoma), and 
the cable itself starts pulling apart first.


Ray Walters
ray at solarray.com
President, SolarRay, Inc.
NABCEP Certified Solar PV Installer
BS Mechanical Engineering, UT Austin 88
Returned US Peace Corps Volunteer 

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