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Old 02-02-2007, 11:54 AM   #1
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pd2160 wiring

So I need to wire my new battery to my new converter. What guage wires should I use for the battery cables? I have the converter already wired to the fuse panel but I'm not sure how to wire the battery. Where do I run the positive from the battery to and with what size breaker inbetween? Also, do I need to ground the battery or just the converter and fuse panel? Lastly, how do I wire the negative of the battery and does it need a fuse as well? Thanks. I don't have an ammeter right now so this is to wire it without. Thanks so much. You guys are awesome. LET THERE BE LIGHT!!!

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Old 02-02-2007, 12:25 PM   #2
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This thread will introduce some ideas on wiring but more importantly has a link to a wiring diagram in post 4 by 68 Overlander:


5 meter Langford Nahanni

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Old 02-02-2007, 02:52 PM   #3
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I think I would use #6 wire with 50a circuit breakers. The battery negative can go to the converter, then to the ground, or it can go to ground first. You might want to put a big fuse on the battery ground.

I wired my positive from the battery to a 150a disconnect switch, through a 50 amp circuit breaker, then to a copper buss made from a squished piece of copper tubing. The converter was wired directly to the copper buss, and another #6 wire came off the buss through another 50 amp circuit breaker to the fuse panel.

The first picture shows the general layout of the battery switch, and the Converter mounted vertically on the wall.

Second picture shows the battery switch panel removed to show the wiring to the circuit breakers, mounted above the converter. Red is positive, white is negative. On the wall to the rear you can see the connections for the ground wiring, including the green #8 chassis ground from the rear of the converter, and the lugs for the battery ground connection. All the lugs are tapped directly into a frame channel and coated in anti-oxidant paste.

The third photo shows a detail of the circuit breakers and copper connecting buss bar.
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Old 02-05-2007, 08:26 PM   #4
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So I think I get the positive part of the battery wiring but still need clarification on the negative. So does the battery negative go straight to the fuse panel, or do I need a bus that has the negative go to it, the converter and a ground. How should the battery be grounded? Thanks
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Old 02-05-2007, 10:18 PM   #5
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Good stuff posted above and markdoane has a great photo set but lets not get in the weeds too far if you just want to connect a simple converter to your system. If you have it wired to the fuse panel already, you are half way there. Just continue on from the distribution panel to the battery with a 50 amp fuse near the battery and voil&#224;, you're done. I would bond the converter to chassis ground with that rinky dink little terminal on the side of the converter too.
As for the wire size?...go as big as you can stuff in the terminals for optimum performance (resistance, voltage drop) but I would not go less that 6 AWG.
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Converters, Inverters, Monitors, EMS, Zamp Solar
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