Windless cable size, cable manufacture and battery type? - Page 2 - SailNet Community
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post #11 of 26 Old 02-12-2010
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I come up with 4/0 for a 50' run @ 85 amps with a 2% drop..

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post #12 of 26 Old 02-12-2010
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I agree with Maine Sail. 4/0 is best, 2/0 works as it has a 3% voltage drop. The manual gives a recommendation that is way too small. See below.
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post #13 of 26 Old 02-18-2010 Thread Starter
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OK I called (finally found the support #) Lewmar and talked to Josh who said I should use 2 AWG wire for the 25’ run. That seems about right I am guessing.
H3 12v windlass

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Chip
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post #14 of 26 Old 02-18-2010
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Josh is an idiot. Umm...what part of the wire is severely undersized did you not understand??

For a high-load device like this, you want a maximum of 3% voltage drop, preferably less.... You really want to oversize the wire a bit to allow for the eventual increase in resistance that happens with most wiring as it ages. Maine Sail, Mitiempo and I all are recommending that you go with 4/0 wire for a reason.

The greater the voltage drop, the higher the amperage the motor will draw, and the more likely the motor is to burn out. Using 2 AWG wire for that run will lead to a 5.7% voltage drop under ideal conditions. Once the wire and terminals start getting older, you'll see a bigger drop than that.

From the Lewmar Horizon 400 manual:

Quote:
Check the voltage across the motor leads with the windlass on. (Proper voltage is 13.5 volts. Constant low voltage will destroy the motor).
Is the voltage low? (Below 11.0 volts on a 12 volt system).
By using 2 AWG wire, you’re pretty much guaranteeing that this will be a recurring issue for your windlass.


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OK I called (finally found the support #) Lewmar and talked to Josh who said I should use 2 AWG wire for the 25’ run. That seems about right I am guessing.
H3 12v windlass

Thanks,
Chip

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post #15 of 26 Old 02-18-2010
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Quote:
Originally Posted by SanDiegoChip View Post
OK I called (finally found the support #) Lewmar and talked to Josh who said I should use 2 AWG wire for the 25’ run. That seems about right I am guessing.
H3 12v windlass

Thanks,
Chip
Are you 100% positive that Josh did not mean 2/0 (00) wire? There is a HUGE difference between 2 gauge wire and 2/0 gauge wire.

Sailingdog is right and the info you have been previously give is spot on when using basic ABYC and industry electrical standards. The calculations are NOT difficult. Plug in the round trip length, desired voltage drop and the amperage consumed... 2 gauge wire is not appropriate for this windlass at 50 feet and 80-+ amps unless you have a very short run, or the battery is right next to the windlass..

If 2 gauge wire was in fact Josh's advice, and you told him this was a 25' run (50 feet round trip), then he does not belong in the electric winch/windlass tech support department, he belongs in the shipping department..

I will be quite horrified if in fact Josh told you 2 gauge and not 2/0 for a 50 foot run on 80+ amps....

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post #16 of 26 Old 02-18-2010 Thread Starter
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I got a call back into Josh at Lewmar for clarification on the 2 AWG or 2/0 AWG. I did use the calculators for loss. He must have meant 2/0 wire or I heard wrong. I have spent a bundle of cash and time and my wife and I are bruised and cut from the bow roller and bow pulpit re-install. We do not want to cheap out on this final part of the project and ruin all the fine work we have done. No matter what he says 4/0 is the way we will go. In this case bigger is better and I had been planning on 4/0 anyway. Just was not sure. Before I spent the $$ I wanted to be sure I was not just wasting money. Even though I have been checking the calculator for wire size I just do not seem to get it. I understand the loss, voltage drop some. Any way it makes sense what you say. I can understand that.
It is 25' one way or 50' round trip.

I get:
2 AWG

Voltage drop = 0.683
Voltage at load end of circuit = 11.317
Per Cent voltage drop = 5.69

2/0 AWG
Voltage drop = 0.34
Voltage at load end of circuit = 1.66
Per Cent voltage drop = 2.83

There is a big difference.
We will go with 4/0 (0000) wire.
Anything else I should watch for?
Like end fittings etc?
Thanks,
Chip

Last edited by SanDiegoChip; 02-18-2010 at 02:16 PM.
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post #17 of 26 Old 02-18-2010
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If I'm reading this chart correctly, it does say that you should use a 2awg for a 50-80' run. On the Lewmar windlass I just bought, the manual says that you want to stay below a 10% drop, but I opted for just a 2.86% to be safe.



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OK I called (finally found the support #) Lewmar and talked to Josh who said I should use 2 AWG wire for the 25’ run. That seems about right I am guessing.
H3 12v windlass

Thanks,
Chip

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post #18 of 26 Old 02-18-2010
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Go with good terminals, like those from Ancor or FTZ and either get a proper battery terminal crimping tool or order the cables from Genuinedealz.com and have them crimp the terminals on for you. Add adhesive lined shrink tubing to further seal them.
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Anything else I should watch for?
Like end fittings etc?
Thanks,
Chip

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post #19 of 26 Old 02-18-2010
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I just ordered this Heavy Duty Battery Crimping tool for $99 shipped.

EZ B795 Heavy Duty Battery Crimping Tool - eToolDirect

If you want, I'll let you know how it is when I get it.

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post #20 of 26 Old 02-18-2010 Thread Starter
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I have been looking at Genuinedealz.com and will take the final, final measurement tonight with my wife and then order tomorrow (Friday), I will order the 4/0 cables with the ends on and shrink tubing.
We will be ordering our battery cables as we replace the existing ones so they will get ends crimped on at that time. So a crimping tool would be nice however I think we can get by without it. Now for crimping terminal ends I have been eying a ratcheting crimping tool though, that seems something like the gift to myself that will keep on a crimping for me.
Chip
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