HOW TO CORRECTLY CONNECT
DEEP CYCLE BATTERIES AND CHOOSE
THE RIGHT CABLE SIZING
CONNECTING
DEEP CYCLE
BATTERIES
How to correctly connect deep
cycle batteries and choose the
right cable sizing.
There are several ways to wire multiple batteries to achieve the
correct battery voltage or capacity for a particular DC installation.
Wiring multiple batteries together as one big bank, rather than
having individual banks makes them more ecient and ensures
maximum service life.
Series Connection
Wiring batteries together in series will increase the voltage while
keeping the amp hour capacity the same. For example; 2 x 6V
150Ah batteries wired in series will give you 12V, but only 150Ah
capacity. 2 x 12V 150Ah batteries wired in series will give you 24V,
but still only 150Ah.
Parallel Connection
Wiring batteries together in parallel has the effect of doubling
capacity while keeping the voltage the same. For example; 2 x
12V 150Ah batteries wired in parallel will give you only 12V, but
increases capacity to 300Ah.
Series/Parallel Connection
This is a combination of the above methods and is used for 2V, 6V or
12V batteries to achieve both a higher system voltage and capacity.
For example; 4 x 6V 150Ah batteries wired in series/parallel will give
you 12V at 300Ah. 4 x 12V 150Ah batteries can be wired in series
/parallel to give you 24V with 300Ah capacity.
Battery Cable Connections:
The cables that join your batteries together play an important part
in the performance of your battery bank. Choosing the correct size
(diameter) and length of cable is important for overall eciency.
Cables that are too small or unnecessarily long will result in power
loss and increased resistance.
When connecting batteries in series, parallel or series/parallel the
cables between each battery should be of equal length. As you
can see in the diagrams below all the short cables connecting the
batteries together are the same length and all the long cables are
the same length. This links the batteries together with the same
amount of cable resistance, ensuring that all batteries in the system
are working equally together.
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Particular attention should also be paid to where the main system
cables are connected to the battery bank. All too oen the system
cables supplying the loads are connected to the first or “easiest”
battery to get to in the bank, resulting in poor performance and
service life. These main system cables that run to your DC
distribution (loads) should be connected across the whole bank
as illustrated in the diagrams to the le. This ensures the whole
battery bank is charged and discharged equally, providing
optimal performance.
The main system cables and the cables joining the batteries together
should be of sucient size (diameter) to handle the total system
current. If you have a large battery charger or inverter you want to
make sure that the cables are capable of carrying the potentially
large currents that are generated or consumed by these pieces of
equipment, as well as all your other loads.
Series Connection:
Batteries are coupled in series to gain higher voltage, for instance
24 or even 48 Volt. The plus pole of each battery is connected to
the minus pole of the following one, with the minus pole of the first
battery and plus pole of the last battery connected to the system.
This type of arrangement shown is a 24v, 120Ah bank.
Parallel Connection:
Parallel coupling involves connecting the plus poles of multiple
batteries to each other and the same with the minus poles. The
plus of the first battery and the minus of the last battery are then
connected to the system. This type of arrangement is used to
increase capacity (in this case 12v 240Ah).
Series/Parallel Connection:
A combination of series and parallel connections is required if you
need for example a 24 Volt battery set with a higher capacity. The
battery should then be cross-wired to the system using the plus
pole of the first and minus pole of the last battery. This type of
arrangement shown is a 24v, 240Ah bank.
Batteries connected in series.
Batteries connected in parallel.
Batteries connected in
series / parallel.
Cable Sizing
In an independent power system, you generally would find an
inverter and battery charger system working for the common
goal of providing power. What ties each of these together are the
cables to supply the power to run to or from the batteries or DC
distribution. Unfortunately, the most common installation error
is to under-size cables to the load/s or from the recharge sources.
Proper installation is primarily a matter of sizing a cable to match
its task, using the correct tools to attach terminals, and providing
adequate over-current protection with fuses and circuit breakers.
Cable sizing is simple enough. It is a function of the length of a
cable (measuring from the power source to the appliance and
back), and the current (amperage) that will flow through it. This
can be found by checking the label on the appliance in the circuit,
or the specifications sheet for the appliance. The longer the cable,
or the higher the amperage, the bigger the cable must be to avoid
unacceptable voltage losses. And there should always be plenty
of extra margin for safety because an appliance may actually use
more current than what it is rated for because of heat, low voltage,
extra load and other factors.
For 12V circuits, the relationship between cable length, current
flow, and cable size is given in the table below. Note that you have
two circuit types, Critical & Non Critical. The “critical” circuit is
based on a 3% voltage loss in the cable, while the “non-critical”
circuit is based on a 10% voltage loss. What this means is that when
the circuit is fully loaded (i.e. operating at rated amperage), the
voltage at the appliance will be 3% or 10% below that at the battery.
For example, if the battery is at 12.6 volts, the appliance will be
seeing 12.2 volts (3% loss), or 11.34 volts (10% loss).
Many appliances (notably lights) will run fine with a 10% voltage
loss, but others are particularly sensitive to such losses (notably
charging circuits, and some electric motors). In general, given the
harsh realities of the RV & marine environment, it’s better to use
the 3% volt drop table when sizing cables, rather than the 10%
table. There’s never a performance penalty if a cable is marginally
oversized; there is always a performance penalty (and possibly a
safety hazard) if it’s undersized.
Page 3 August 2024 (V1.1)
Other important points to bear in mind when
wiring boats or RV’s:
The ground (negative) cable is as much a part of a circuit as the
positive cable; it must be sized the same. In general, each
appliance should be supplied from the distribution panel with its
own positive and negative cables, although lighting circuits
sometimes use common supply and ground cables to feed a
number of lights (in which case the supply cables must be sized
for the total load of all the lights).
For 24v systems, the cables size is half that of a 12v setup.
Always read product recommendations, or check with your
supplier to know and understand exactly what size cable is
required for your products.
A detailed cable sizing chart is listed on the page 7. The cable
sizing table is used by running across the top row until the
column with the relevant amperage is found, and then moving
down the lehand column until the row with the relevant distance
is reached.The colour coding in the body of the table at the
intersection of this row and column is the wire size. Compare this
with the Cable Conversion Table to see what size cable to use.
The AWG (American Wire Gauge) is used as a standard method
of denoting wire diameter, measuring the diameter of the
conductor (the bare wire) with the insulation removed. AWG is
sometimes also known as Brown and Sharpe (B&S) Wire Gauge.
Most Australian Auto Electricians use the B&S scale.
Also listed is a conversion chart from AWG/B&S to mm². This
table gives the closest equivalent size cross references between
metric and American wire sizes. In Europe and Australia, wire
sizes are expressed in cross sectional area in mm².
• All circuits should be as high as possible with no connections in
or near bilge water or damp areas.
• All cable lug connections should be well crimped and NOT
soldered
• It is preferable to use tinned cable where possible in a marine
environment
• Use twisted-pair cable for any wiring within 1m of a compass.
Detailed cable sizing chart is listed
on the last page.
Page 4 August 2024 (V1.1)
• Never tap into existing circuits when installing new equipment;
run a properly-sized new duplex cable (positive and negative
cable in a common sheath) from the distribution panel (or a source
of power) to the appliance.
• It is recommended to label all cables at both ends, and you
should keep an updated wiring plan on board, to aid in future
troubleshooting.
• Each circuit should have an independent ground cable, and all
the ground cables should eventually be tied back to a common
ground point/bus bar which is grounded to the battery negative;
if devastating stray current is to be avoided, this is the only point
at which the grounds should be interconnected.
• Unless in a conduit, cables should be supported at least every
450mm.
• Although black is often used for DC negative, it is also used for the
live wire in AC circuits in the USA. That means there is potential for
dangerous confusion. DC and AC wiring should be kept separate;
if they have to be run in the same bundle, one or the other should
be in a sheath to maintain separation and ensure safety.
• Be sure to isolate the batteries before working on the DC system,
and, for safety sake, shut o all potential AC power sources (the
shore power, and on-board AC generator, or an inverter)
Page 5 August 2024 (V1.1)
Page 6 August 2024 (V1.1)
2. Circuit Type 1. DC Amps
10%
Voltage Drop
Non Critical
3%
Voltage Drop
Critical
5A 10A 15A 20A 25A 30A 40A 50A 60A 70A 80A 90A 100A 120A
150A
200A
0-6 m
0-2 m
6-9 m 2-3 m
9-15 m 3-4.5 m
15-19 m 4.5-6 m
19-24 m 6-7.5 m
24-30 m 7.5-9 m
30-40 m 9-12 m
40-51 m 12-15 m
51-61 m
15-18 m
18-21 m
21-24 m
24-27 m
27-30 m
30-33 m
33-37 m
37-40 m
3. Cable Length In Metres
Standard Unit
AWG
0000 000 00 0 1 2 4 6 8 10 12 14 16
Diameter (mm)
11.68
10.40
9.27 8.25 7.35 6.54 5.19 4.11 3.26 2.59 2.05 1.63 1.29
Cross Section (mm
2
)
107.1 84.9 67.5 53.5 42.4 33.6 21.2 13.3 8.4 5.3 3.3 2.1 1.3
Colour Code
IMPORTANT:
Measurements of Diameter and Cross Section of cable does not include insulation. Cable Icons are for representational purposes
Match the correct coloured symbol from the previous step using the table below to find the
cable size and specifications.
only and are not to be taken as actual cable sizes.
Note: Sometimes gauges are expressed as follows (e.g. 4/0 is the same as 0000). AWG stands for American Wire Gauges.
Cable Sizing Selection Chart
Step 1. DC Amps
Step 2. Circuit Type
Step 3. Cable Length
Step 4. Correct Cable Size
Select the correct circuit type. Examples of Non Critical circuit are general lighting,
windlasses, bait pumps, general appliances. Examples of Critical circuits are panel main
feeders, bilge blowers, electronics, navigation lights.
Find the correct cable length range. Please note that the cable length is total length of the
positive and negative wires. I.E. Distance from battery to appliance multiplied by 2.
Intersect the DC Amps with the cable length range to identity the correct coloured symbol.
Step 5. Cable Conversion Table
Locate the current flow in amps of your circuit along the top of the chart below.
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