Typical Applications

Connecting the Inverter to the Battery Pack
The core application of this series of cables is the transmission of power from the battery to the inverter on the DC side. The required cable gauge varies significantly depending on the inverter’s power rating and the system voltage (12V/24V/48V). For example, when transmitting 2,400 W of power in a 12 V system, the current at the battery end can exceed 200 A, requiring 2 AWG or thicker cable to control voltage drop and temperature rise. The high-temperature resistance of the silicone insulation allows the cable to operate safely in high-temperature areas near the inverter.

Automotive/Motorhome/Marine Battery Systems
Within vehicle electrical systems, this product is suitable for applications such as connecting the starter battery to the auxiliary battery, powering high-power winches, and supplying power to on-board inverters. The combination of tinned copper conductors and silicone insulation enables it to withstand high temperatures and vibrations in the engine compartment, as well as salt spray corrosion in coastal environments. The pre-crimped ring terminals can be fitted directly onto standard battery terminal bolts (M6/M8/M10); for installation torque, please refer to the battery or equipment manual (typical value: 5 N·m).

Energy Storage Systems (ESS/BESS)
In residential and commercial/industrial energy storage systems, this cable is used for parallel connections between battery clusters and for DC busbar connections from battery clusters to the PCS (Power Conversion System). The halogen-free and flame-retardant properties of the silicone rubber insulation meet fire safety requirements for indoor installation, whilst its wide temperature range performance is suited to the internal environment of containerised energy storage cabinets.

Selection Guide

Step 1: Determine the continuous current
Calculate the current based on the equipment’s maximum continuous power and the system’s minimum operating voltage. For inverter applications, use the maximum DC input current adjusted for inverter efficiency or the maximum DC current specified by the manufacturer, rather than simply dividing the power by the nominal voltage.

Step 2: Apply a safety factor
For continuous loads (operating continuously for more than 3 hours), it is recommended to determine the minimum current-carrying capacity requirement of the cable as the actual current multiplied by 1.25.

Step 3: Verify Voltage Drop
When routing cables over long distances, voltage drop may become a decisive factor in selection. It is recommended that the design target be no more than 2%–3% of the system voltage. The formula for calculating voltage drop is ΔV = I × R × 2L (where 2L is the round-trip path length). If the cable meets the current-carrying capacity requirements but the voltage drop exceeds the limit, a larger cable gauge must be selected.

Step 4: Confirm Terminal Sizes
Select the appropriate ring terminal bore size based on the thread specifications (M6/M8/M10) of the battery or equipment terminals. During installation, ensure that the flat contact surface of the terminal makes full contact with the terminal post and tighten to the torque specified by the equipment manufacturer.

Installation and Safety Precautions
Polarity verification: Before connecting to the inverter, always use a multimeter to verify that the polarity of the battery’s positive and negative terminals matches that of the inverter terminals. Inverters typically do not feature reverse connection protection; reverse connection will result in permanent damage to the equipment.

Overcurrent protection: Install a DC-rated fuse or circuit breaker on the battery positive circuit as close as possible to the battery terminals. The fuse rating should be higher than the maximum load current but lower than the cable’s current-carrying capacity.

Terminal Tightening: Ring terminals must lie flat against the terminal posts and be tightened to the torque specified in the equipment manual (typically 2–5 N·m, depending on the terminal specification). Insufficient torque will result in increased contact resistance and heat generation, whilst excessive torque may damage the terminals or terminal posts.

Cable Protection: Avoid routing cables near sharp edges, high-temperature heat sources or moving parts. Although silicone insulation offers excellent temperature resistance, its mechanical strength is lower than that of materials such as cross-linked polyolefin; it is therefore recommended to fit a protective sleeve when passing through metal openings.

The use of CCA wire is prohibited: Copper-clad aluminium (CCA) conductors have a significantly lower current-carrying capacity than pure copper for the same wire gauge, which can lead to severe overheating. Please ensure that the conductors in this product are made of tinned pure copper; CCA must not be used as a substitute.