Hole lug narrow enough to connect to 3000w renogy inverter with 4/0 wire

Where can I get a lug narrow enough to pass through plastic terminal insulator on Renogy 3000w inverter. The lugs I currently have are just too large. I can make it work by taking off the plastic insulators/guards on the inverter, but that is just asking for it. Any information would be greatly appreciated!

 

Tough one - 4/0 is a damn large wire and so are the lugs. Possibly 3D print or make custom guards (i.e., from thick plastic project boxes)?

BTW: Are you planning to utilize 3kW out of the inverter fully? If not, you could consider scaling down and using a smaller wire and fuse (to protect the wire) for lower amperage/demand.

 

I considered this, but yes, I will sometimes consume pretty much the full capacity of the inverter. I find it nearly hard to believe that it is even LEGAL to make a large inverter such as a 3000 watt inverter! So many people have to run a 4/0 wire due to such high amperage required and length of the cable. It only seems right to build an inverter capable of accommodating the larger gauges of wire, especially on a 3000 watt inverter!

 

Everything is legal in China... to sell here.

 

The problem is the battery voltage. 12V battery feeding a 3000W inverter is extreme.

If I were to do a new setup in my camper I would run 24,36,or 48V battery setup. You could run a 3000W inverter on some reasonably size cables at <100 amps at 36 or 48V. Even 24V would be a measly 135A. Unfortunately the Renogy batteries i bought don't allow series wiring so I am stuck at 12V. I've thought about cutting them open and building my own battery with the cells and with a different BMS.

 

The current plan of the OP is to use a 350 amp fuse...

 

You are correct. I did this setup in my travel trailer. Victron Multiplus 3000, fed by (at the time) three Battle Born LiPo 100 AH batteries. Made two mistakes: 1) using Amazon "chinesium" bus bars, and 2) 4 AWG wire.

Powering a microwave oven and coffee maker burned the bus bars and melted the insulation off the wiring. Was lucky nothing caught on fire.

My setup now has 4/0 AWG with a Victron 1000A bus bar. No issues, all works great even with five Battle Born batteries!


OP is right to want the heavy stuff but IMO it's a waste in the truck. Recharging is important- even with 500 AH I can't sustain a microwave/AC/coffee maker for very long. The truck isn't going to do that, so you'll need a generator to do the recharge.

 

This setup is partly hobby. Yes, it's an expensive hobby. I do have a generator to do the recharging as needed, but I won't be needing this setup for any extended periods. The heaviest this setup will power is perhaps two 120v 15 amp saws along with a 4 port Dewalt battery charger. The saws won't run continuous obviously, but for the brief periods (a few seconds) they are both running, I don't want to pop any breakers or fuses. 3000w is overkill for me, but better too much than not enough. The 3000w inverter will undoubtedly have an easy life, as I do not foresee ever using it at full capacity for extended periods. However, it is there if I want it and the option to add more batteries always exists.

Fishing trips to Ocracoke Island is also on the list of intended uses. Just on one battery, I was able to power a 58qt electric cooler for 4 days with no charge! Now that the 2nd battery is installed along with (6) 100 watt solar panels and a 60 amp MPPT controller, the wide opened beach of Ocracoke will give the option of solar recharging from sun up to sun down. No A/C, no coffee maker, no high drain devices to speak of. What the future holds, I don't know, but I think I have a good start. Modifications will be made as needs expand.

 

Agree that it's an expensive hobby!!! The solar panels help a lot. I have 800w solar (600 currently hooked up, one panel is idle at the moment) on my trailer and a Victron 100/50 MPPT controller. With the 600w active while out at the desert last month the panels were able to charge the batteries from 75% or so to high 90% range in an afternoon, so you're not doing too bad with the solar that you have. Burst use of the microwave while the coffeemaker was going was what took the percentage down (according to my BMV-712 meter). I didn't try my A/C, but I am sure the current draw from that will surely deplete the batteries in a matter of an hour or so. Sounds to me though that your draw/recharge rate should do you just fine. Good luck!

 

Thank you! I'm enclosing a photo of the setup (minus the 40 amp AC to DC charger. And every time I write that, I start humming "Thunderstruck" ) I'm running the same as you on the 600w panels, but I will probably add another Renogy 400 watt combo. If I ever add a camper with A/C to the mix, I'll need a LOT more batteries.