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Fusing Battle Born 12 volt 270AH battery 300 amp BMS

Tadsher

Hobbyist Learning About Solar and Solar Components
Joined
Feb 5, 2024
Messages
139
Location
Boston
If my understanding is correct I need a Fuse 1.25% of battery output. The 2 Battle Born 12 volt 270 AH (run in series) batteries I have are rated at 300 amps and 500 amps surge. Is a 375/400 amp class T fuse the correct fuse size? Will a 320 amp fuse alright like this one? https://www.amazon.com/Blue-Sea-Systems-Class-Insulating/dp/B001VJ03LA/?th=1 ~ 12 volts because that is the inverter I have for this project right now.

What size wire would I use? 300 amps or 500 amps? 1/0 to bus bar alright? The load will be a 3000 watt inverter drawing about 350 amps.
 
Here is the math -

12.8v battery - you mention 300amp output on the BMS with surge to 500amps.

Ordinarily I suggest fusing against the max current of the BMS - not the surge - the fuse will hold up under a surge if sized right. But at 300amps the other factor is the inverter you are choosing.

300a * 12.8v = 3840W --- is your inverter 3000w? 3500w?

Fuse based on the math is

300a * 1.25 = 375amps

But if your inverter is smaller than that say 2000w

2000w / 12.8v = 156a * 1.25 = 195w - so you fuse at 200amps.

2500w / 12.8a = 195a * 1.25 = 244amps = fuse at 250amps.


Various wire tables here

wire tables

Welding wire for 375amps is 4/0
Welding wire for 250amps is 1/0
Welding wire for 200amps is 2awg

Now the 200amp and 250amp wire sizes are right close to the edge of capacity so you step up one size so they run cool and can respond to surges.

So 2/0 for 250amp and 1/0 for 200amps .

You can't go wrong oversizing the wire and fuse to your needs, it will cost a bit more but will run cooler. Fuses have more resistance as they decrease in amp capacity so the class T for 370amps will run cooler than ther class T for 200amps for the same current pushed through it. But you can't upsize the fuse without also upsizing the wire.

The major drag about larger wires is they are harder to fit and bend in tight places.

For welding wire windy nation is the place to go and for battery wire batterycableusa is a good place. You can get raw cable, or of you know the length you can get them pre-crimped with whatever lugs you want.... this is where the tight spaces can be handled by getting them to crimp lugs that bend at 45 or 90 degrees or a left or right bend to be able to just bolt them down.

If you decide to make your own cables buy a good Temco or other quality hydraulic crimper... don't waste your money on the cheap AMZCNC or other junk on amazon - it will make bad crimps and wings... and the lugs by Ancor, Temco, Selterm, and a few others are fine... if the name of the vendor sounds like a frypan hit the wall and bounced twice it will be undersize, oversized, or thin...
 
Last edited:
Batteries in parallel not series then.

I would use 2/0 wire and a 250A fuse.

That Amazon link is for a fuse holder without a fuse included btw.
"Batteries in parallel not series then."

Yes I get confused it will be in parallel, Thank you

"That Amazon link is for a fuse holder without a fuse included btw."

That ad is shows a fuse, thanks for pointing that out.
 
Here is the math -

12.8v battery - you mention 300amp output on the BMS with surge to 500amps.

Ordinarily I suggest fusing against the max current of the BMS - not the surge - the fuse will hold up under a surge if sized right. But at 300amps the other factor is the inverter you are choosing.

300a * 12.8v = 3840W --- is your inverter 3000w? 3500w?

Fuse based on the math is

300a * 1.25 = 375amps

But if your inverter is smaller than that say 2000w

2000w / 12.8v = 156a * 1.25 = 195w - so you fuse at 200amps.

2500w / 12.8a = 195a * 1.25 = 244amps = fuse at 250amps.


Various wire tables here

https://diysolarforum.com/threads/robbob2112-answer-thread.84402/post-1286275

Welding wire for 375amps is 4/0
Welding wire for 250amps is 1/0
Welding wire for 200amps is 2awg

Now the 200amp and 250amp wire sizes are right close to the edge of capacity so you step up one size so they run cool and can respond to surges.

So 2/0 for 250amp and 1/0 for 200amps .

You can't go wrong oversizing the wire and fuse to your needs, it will cost a bit more but will run cooler. Fuses have more resistance as they decrease in amp capacity so the class T for 370amps will run cooler than ther class T for 200amps for the same current pushed through it. But you can't upsize the fuse without also upsizing the wire.

The major drag about larger wires is they are harder to fit and bend in tight places.

For welding wire windy nation is the place to go and for battery wire batterycableusa is a good place. You can get raw cable, or of you know the length you can get them pre-crimped with whatever lugs you want.... this is where the tight spaces can be handled by getting them to crimp lugs that bend at 45 or 90 degrees or a left or right bend to be able to just bolt them down.

If you decide to make your own cables buy a good Temco or other quality hydraulic crimper... don't waste your money on the cheap AMZCNC or other junk on amazon - it will make bad crimps and wings... and the lugs by Ancor, Temco, Selterm, and a few others are fine... if the name of the vendor sounds like a frypan hit the wall and bounced twice it will be undersize, oversized, or thin...


It is a 12 volt 3000 watt inverter, output is 120 volts.
 
Here is the math -

12.8v battery - you mention 300amp output on the BMS with surge to 500amps.

Ordinarily I suggest fusing against the max current of the BMS - not the surge - the fuse will hold up under a surge if sized right. But at 300amps the other factor is the inverter you are choosing.

300a * 12.8v = 3840W --- is your inverter 3000w? 3500w?

Fuse based on the math is

300a * 1.25 = 375amps

But if your inverter is smaller than that say 2000w

2000w / 12.8v = 156a * 1.25 = 195w - so you fuse at 200amps.

2500w / 12.8a = 195a * 1.25 = 244amps = fuse at 250amps.


Various wire tables here

https://diysolarforum.com/threads/robbob2112-answer-thread.84402/post-1286275

Welding wire for 375amps is 4/0
Welding wire for 250amps is 1/0
Welding wire for 200amps is 2awg

Now the 200amp and 250amp wire sizes are right close to the edge of capacity so you step up one size so they run cool and can respond to surges.

So 2/0 for 250amp and 1/0 for 200amps .

You can't go wrong oversizing the wire and fuse to your needs, it will cost a bit more but will run cooler. Fuses have more resistance as they decrease in amp capacity so the class T for 370amps will run cooler than ther class T for 200amps for the same current pushed through it. But you can't upsize the fuse without also upsizing the wire.

The major drag about larger wires is they are harder to fit and bend in tight places.

For welding wire windy nation is the place to go and for battery wire batterycableusa is a good place. You can get raw cable, or of you know the length you can get them pre-crimped with whatever lugs you want.... this is where the tight spaces can be handled by getting them to crimp lugs that bend at 45 or 90 degrees or a left or right bend to be able to just bolt them down.

If you decide to make your own cables buy a good Temco or other quality hydraulic crimper... don't waste your money on the cheap AMZCNC or other junk on amazon - it will make bad crimps and wings... and the lugs by Ancor, Temco, Selterm, and a few others are fine... if the name of the vendor sounds like a frypan hit the wall and bounced twice it will be undersize, oversized, or thin...

I have some 4/0 welder wire and I might use some of that. Thanks

It is a 3000 watt inverter
 
So

3000w / 12.8v = 234a * 1.25 = 292amps so I would fuse at 300amps. If you fuse at 250 and use anywhere close to the 3000w for a while the fuse will run hot.

Still 2/0 cable for welding wire or battery cable. So 4/0 will work fine

And if you have the 4/0 welding wire and it will fit the inverter - some have screw terminals - then fuse at 350 and it will run cool to the touch.
 

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