2006/08/18 - RE: Great source for wire and connectors [TANKS] (Steve Tyng)

What you describe will work fine though may be a little overkill. Remember that the RS80D is current limiting so your EV's will never see more than 80amps. The Cromwell has only one 60A fuse wired between the RS80D and the batteries. I've never blown a fuse. I'm using 6 gauge wiring from the batteries to the controller (it's what I had laying around). I made custom battery connectors using length's of "Square D" aluminum ground bus bar material. I connected the EV's directly to the RS80D using the stock wiring that they came with.

When it comes to this high current wiring you must double check, and then TRIPLE CHECK everything before testing with full current. Put a low amp fuse in place for your initial testing. Make sure of your polarity on your controller. Reversing this is an easy way to let the magic smoke out.

Don't forget that the EV's need to be modified for safe use in a reversing application. The case is internally grounded. When you reverse a stock EV Warrior the case will have a positive charge on it. The motor needs to be disassembled and a little grounding do-hicky removed from the brush plate.

Since you brought up connectors Steve, I have some questions. I am using the RS-80D with EV Warriors at 24V. My batteries are two 18AH PowerSonics. I have some of the Anderson PowerPole connectors, but they are rated for 50 amps. My question would be, will those 50 amp connectors (using 10 guage wire) be sufficient to run from my RS-80D to my EV Warriors? The EV Warrior connectors and cables are also 10 guage wire. The contacts in the 50 amp connectors are rated for 75 amps. Each EV Warrior motor will have a 70 amp breaker inline rated for applications up to 48V. My main power cables from the battery to the RS-80D will be 8 guage going through a 100 amp breaker that is rated up to 48V operation. So the main power breaker should trip if more than 100 amps get passed to the RS-80D and the EV Warrior breakers should trip if the EV's starts drawing more than 70 amps. Do you guys think that this setup will be sufficient? By the way, my tank weight is estimated in the 60-75lb. range once complete.

Derek (no smoking/burning wires for me) Engelhaupt

From:	"Steve Tyng" <STyng-at-ACPTrust.com>
Subject:	RE: Great source for wire and connectors [TANKS]
Date:	Fri, 18 Aug 2006 15:01:58 -0400
Reply-To:	tanks-at-rctankcombat.com