10AWG to 8AWG

[ebike11]

Hi guys
Would there be any significant gains from increasing power wire between lipo packs and to the controller (sabvoton in my case) from 10awg to 8awg?
Im using 10awg with xt90s which fit nicely but with connecting packs, there is a lot of soldering and multiple xt90 connectors.
Just wondering if its worth it.
Thanks!

 

[Tommm]

Dont bother under 70a continuous or 1 meter of cable (3ft).

 

[ebike11]

Dont bother under 70a continuous or 1 meter of cable (3ft).

My bike pulls between 100 and 200A when taking off and being hard on the throttle. Plus my wiring is over a meter with multiple packs to connect to

 

[goatman]

why do all the xt90s?

 

[Tommm]

Dont bother under 70a continuous or 1 meter of cable (3ft).

My bike pulls between 100 and 200A when taking off and being hard on the throttle. Plus my wiring is over a meter with multiple packs to connect to

If by 100 and 200 you mean battery amps, you will see about a 3% benefit.
The 8ga won't go in the xt90 without some editing, you have to cut the outermost strands in a circular fashion before it will fit.

 

[ebike11]

Dont bother under 70a continuous or 1 meter of cable (3ft).

My bike pulls between 100 and 200A when taking off and being hard on the throttle. Plus my wiring is over a meter with multiple packs to connect to

If by 100 and 200 you mean battery amps, you will see about a 3% benefit.
The 8ga won't go in the xt90 without some editing, you have to cut the outermost strands in a circular fashion before it will fit.

Yeah i would need different connectors. What would the next biggest about the xt90?
If i had to trim the wires at the connectors then wouldnt that just bottleneck the wiring? Eventhough i wouldnt have to remove too many strands

 

[Tommm]

Dont bother under 70a continuous or 1 meter of cable (3ft).

My bike pulls between 100 and 200A when taking off and being hard on the throttle. Plus my wiring is over a meter with multiple packs to connect to

If by 100 and 200 you mean battery amps, you will see about a 3% benefit.
The 8ga won't go in the xt90 without some editing, you have to cut the outermost strands in a circular fashion before it will fit.

Yeah i would need different connectors. What would the next biggest about the xt90?
If i had to trim the wires at the connectors then wouldnt that just bottleneck the wiring? Eventhough i wouldnt have to remove too many strands

Resistance of wire is calculated over distance. So it would be a tiny hotter spot, which since the difference is so small would be dissipated through the rest of the wire.

Next step up would be the qs8/qs8-s/ec8/ec8-s
https://endless-sphere.com/forums/viewtopic.php?t=2767#p1317655

It takes up to 6ga/awg

 

[DogDipstick]

The 8ga won't go in the xt90 without some editing, you have to cut the outermost strands in a circular fashion before it will fit.

Yes it will. Certainty. I do it all the time.

I have high quality 6ga that takes about the same volume of silicone 8Ga if you want some. Building a 250A contin battery with it now. Then you wont fit in a XT90. But the 8Ga fits in the XT90 all day.

I gave up building with >8Ga. 8, 10, 12, ect, to small. I am moving to solid custom strip busses for >80% of the distribution network ( like every EV car uses nowadays). 600A capability. Goal is to get the entire power distribution network ( wire, shunt, fuse, breaker,ect) under 10 mOh. Right now my battery is ~ 22mOh.. and the whole including the distribution network is about 35mOh- 40mOh. So I got some 15-20mOh resistance between the cells and the control. Most of this bottlekneck is in the shunt, but I wouldnt give it up for anything, the data is priceless. Shunt really needs 6-8Ga minimum tho. For real power.

 

[Tommm]

The 8ga won't go in the xt90 without some editing, you have to cut the outermost strands in a circular fashion before it will fit.

Yes it will. Certainty. I do it all the time.
I have high quality 6ga that takes about the same volume of silicone 8Ga if you want some. Building a 250A contin battery with it now. Then you wont fit in a XT90. But the 8Ga fits in the XT90 all day.

I think you are using a lower strand count than the standard silicone 1000+ strand wires. In that case it would fit all day. Otherwise, never, any day. :lol:

 

[DogDipstick]

I think you are using a lower strand count than the standard silicone 1000+ strand wires. In that case it would fit all day. Otherwise, never, any day. :lol:

It is the wire used in all EV in production. Not that silicone junk. Takes more current. Higher quality, I buy it by the hundereds of pounds. I know its exact elemental composition. I XRF it. I know how much "copper" is really in that (silicone.. or PVC.... ect... ) "copper" wire. You would be suprised by the elemental compositions of your "silicone 1000 strand".

There is a reason no silicone wire is used in production EV.

Yes, fits. So does 8Ga 1000 strand silicone. I have that here too. Tight, but fits. you cant mess with it at all, or it will fray, and not fit. Takes me 3 seconds to solder 8 and 6 gauge into a barrel.

Measure it.

MM^2

 

[serious_sam]

Yes, fits. So does 8Ga 1000 strand silicone.

Agreed. I am using 8AWG silicone in XT90 and XT150. Fits XT90 ok.

 

[Tommm]

Yes, fits. So does 8Ga 1000 strand silicone.

Agreed. I am using 8AWG silicone in XT90 and XT150. Fits XT90 ok.

I pre tinned my wire, it got too big to fit. After that I never bothered on other connectors, a few strands will always hang out.