Product Overview

This is a ready-made wiring harness designed for high-current DC power transmission applications, with metal ring terminals crimped at both ends, ready for installation straight out of the box. The wire gauges available include 1 AWG, 2 AWG, 3 AWG, 4 AWG, 6 AWG, 8 AWG and 10 AWG, making it suitable for power connections between inverters and batteries, vehicle battery system retrofits, electrical wiring in motorhomes and boats, as well as DC-side wiring for energy storage systems.

The cables feature tinned copper stranded conductors sheathed in silicone rubber, ensuring stable electrical and mechanical performance even under extreme temperatures, humidity, oil contamination and vibration.

Why choose silicone rubber cables?

Standard PVC cables become hard and crack at low temperatures, whilst they soften and deform at high temperatures; in contrast, silicone rubber operates within a temperature range of -60°C to +180°C. This means that a single cable can be used both for outdoor equipment in northern winters and for wiring near heat sources such as inverters and engines, without concern for insulation ageing or embrittlement.

Silicone rubber is inherently halogen-free; it does not release large amounts of toxic fumes when burnt and is self-extinguishing, thereby meeting the fire safety requirements for indoor energy storage cabinets and enclosed electrical compartments. Furthermore, silicone rubber offers excellent resistance to UV radiation, ozone, engine oil and weak acids and alkalis, making it suitable for long-term use in outdoor environments or coastal salt-fog conditions.

The conductor consists of tinned stranded copper, rather than ordinary bare copper or aluminium-clad copper. The tin coating not only prevents oxidation but also forms a stable, low-resistance interface at the crimped terminals, reducing poor contact and heat generation caused by corrosion. The multi-strand structure ensures the cable remains flexible, facilitating bending and routing in confined spaces.

Main Applications

DC-side wiring for inverters: This is the most typical application for this product. When an inverter draws power from a battery, the current is very high; for example, in a 12V system with an output of 2000W, the current at the battery terminal may approach 200A. Insufficient cable cross-section can lead to excessive voltage drops, cable heating, and may even trigger the inverter’s low-voltage protection. The high-temperature resistance and insulation properties of silicone rubber ensure that the cable can operate safely even in high-temperature areas near the inverter.

Vehicle and Marine Electrical Systems: Suitable for connections between starter and auxiliary batteries, powering winches, high-power in-car audio systems or inverters. The combination of tinned copper and silicone rubber withstands high temperatures in the engine compartment, continuous vibration and salt spray corrosion at the ship’s hull. The ring terminals can be fitted directly onto standard battery terminal bolts (M6/M8/M10).

Energy Storage and Battery Packs: In domestic or commercial and industrial energy storage systems, these cables are used for parallel connections between battery clusters and for DC bus connections from battery clusters to power converters. The halogen-free, flame-retardant silicone outer sheath complies with safety regulations for enclosed cabinets.

How to Select Cables

First, calculate the current: divide the maximum continuous power of the equipment by the system’s minimum operating voltage to obtain the maximum DC current. For inverter applications, refer to the manufacturer’s specified maximum DC input current rather than simply dividing the power by the rated voltage.

Next, allow for a margin: for continuously operating loads, it is recommended to select a cable with a current-carrying capacity of 1.25 times the calculated current.

Check the voltage drop: For longer circuits, the voltage drop is often a more critical factor than the current-carrying capacity. It is recommended to keep the total voltage drop within 2% to 3% of the system voltage. The formula is ΔV = I × R × 2L, where 2L is the total length of the circuit path (round trip). If the current-carrying capacity is sufficient but the voltage drop exceeds the limit, a thicker cable must be used.

Terminal Selection: Select ring terminals with a hole diameter corresponding to the thread specifications of the terminals. During installation, ensure that the terminals make full contact with the terminal faces and tighten them to the torque specified by the equipment manufacturer.

Installation Reminders
Check polarity before energising: Inverters generally do not have reverse connection protection; connecting the positive and negative terminals in reverse will immediately burn out the equipment. Before wiring, use a multimeter to verify the polarity correspondence between the battery and the inverter terminals.

Install overcurrent protection: Fit a DC fuse or circuit breaker on the battery positive lead, as close as possible to the battery terminal. The rated value should be higher than the maximum load current but lower than the cable’s current-carrying capacity.

Tighten without over-tightening: Ring terminals must lie flush against the terminal block and be tightened to the torque specified in the manual (typically 2–5 N·m). If the connection is too loose, excessive contact resistance will cause overheating; if too tight, it may damage the terminals or terminal blocks.

Ensure mechanical protection: Whilst silicone insulation offers good temperature resistance, its resistance to cutting and abrasion is inferior to that of cross-linked polyolefin. Where cables pass through metal openings or near sharp edges, install protective sheathing or cable ducts.

Ensure the conductors are made of pure copper: Copper-clad aluminium (CCA) wires have a significantly lower current-carrying capacity than pure copper for the same wire gauge and are highly prone to overheating under high currents. The conductors in this product are made of tinned pure copper; please do not use them in conjunction with or as a substitute for CCA wires.