Sargent EC160 leisure battery positive cable too big

[nikmartin1]

Hi guys, can anyone help. The very thick red cable (16mm I think) coming from my leisure battery (after the split really) seems a bit too big to fit any of the holes on the the Sergant EC160. What do I need to do? Does it need to go into an isolator switch that has a smaller wire coming out of it possibly? Or am I missing something here lol

 

[Pete C]

3 options I think (without seeing photos):

1. Remove individual strands on the cable until it fits - not a great idea, as the strands you have cut down could contact adjacent terminals on the Sergant.
2. Connect a short length of smaller diameter wire - I would solder this carefully, and then heat shrink it properly.
3. Replace the very thick red cable.

Your switch option would work too, but adds another component for no real benefit.

Pete

 

[Boysan]

From the options listed... I would probably take number 2 from Pete C list.... the only thing I would add is that the short cable used would be the maximum that would fit the Sargent.... and I would also use glue lined heatshrink... as it does seem to give it a) better stability... and also adds another level against moisture....

I suppose you could always send an email to the Sargent helpline/customer services and see what they suggest... as they maybe offer an additional item as you can't be the only one with this issue... surely......

 

[Jack T]

Can you not use a copper tube pin crimp to reduce the termination size? Come in round or flat at the end, one would probably solve the issue without reducing cable size.

 

[nikmartin1]

3 options I think (without seeing photos):

1. Remove individual strands on the cable until it fits - not a great idea, as the strands you have cut down could contact adjacent terminals on the Sergant.
2. Connect a short length of smaller diameter wire - I would solder this carefully, and then heat shrink it properly.
3. Replace the very thick red cable.

Your switch option would work too, but adds another component for no real benefit.

Pete

I've just realised how funny it sounded when I wrote "very thick red cable!". Its the one recommended for using with batteries. 16mm I believe. I thought you needed to use the higher rated cable to carry the power from the leisure battery to the Sargent to power the various units.

From the options listed... I would probably take number 2 from Pete C list.... the only thing I would add is that the short cable used would be the maximum that would fit the Sargent.... and I would also use glue lined heatshrink... as it does seem to give it a) better stability... and also adds another level against moisture....

I suppose you could always send an email to the Sargent helpline/customer services and see what they suggest... as they maybe offer an additional item as you can't be the only one with this issue... surely......

Hi Pete, the thick cable (sorry but does sound funny saying that), is the same as the one I used from the main vehicle battery to the split charge relay for the leisure battery. (This came in a kit from a proper company). I assumed it was the ideal size to take from the leisure battery to the Sargent as it was the main feed. I understand that the cables from the Sargent to feed the lights and etc don't need to be that big ( I've got a couple of reels of red and black cables that are 16amp 1mm hat should be fine). I've followed loads of great vids on YouTube to do everything else. There just doesn't seem to be a definitive one on the ideal wiring to link even the basic things. The Sergent is basically an all in one way of linking things. That in itself is pretty straightforward. Originally I assumed you would link the live from the leisure battery to the the main feed into the LB link on the Sargent. Then the various things you need to supply the electric to (lights, water pump etc), had their own dedicated links to screw into that have their own blade fuses. It was just the bit about the fridge wiring that got a little more complicated. Now I understand its because the initial power up of the fridge draws a fair amount of power. Hence a higher ampage cable is required. (the diagram for installation of the Sargent shows the fridge link cables with a 15amp fuse inline. So would my 1mm 16amp rated cable do the job? In theory it should!) And most people seem to link the fridge directly to the battery with its own inline switch. This is no problem. But I was wanting to use the Sergant correctly. I've paid for it and I want to sue (lol).

So, going back to my original query, does anyone know just what size cable to recommend for the main link from the leisure battery to the LB main link to the Sergent? I went on a site that was recommended by one of you guys, and thanks by the way. (Travelvolts). And have seen the cables that he recommends. He recommends 6mm tri rated cable. So have purchased some. (these things are rated at something like 50 amps, a bit overkill I think). And I think they still may be too big to fit in the Sargent. But lets see when they arrive.

Also, the installation pics that came with the Sargent show the main vehicle battery link to the Sargent. As far as I know, I think the Sargent has a built in split relay. I've already wired my own in under the driver seat. (which already works fine - fairly simple) Im wondering if they can both be used together or could it cause a problem. I've kind of taken away, that, when I'm on mains hook up the Sargent will trickle charge the leisure battery.

I know this should all be straightforward. Once I know exactly the ideal way if linking all this stuff, and actually done it and it works, it will pretty easy to rinse and repeat for the next world dominating van project. I can't be the only one out there that is a bit confused (gimme a property and I know what I'm doing) Any advice guys would be greatly appreciated. Sorry for the long post. Nik

 

[nikmartin1]

Can you not use a copper tube pin crimp to reduce the termination size? Come in round or flat at the end, one would probably solve the issue without reducing cable size.

View attachment 90343

Thanks Jack. I must admit I've never seen these tube style reducers before. And I would make sense (and maybe keep things much simpler), but how does everyone else deal with what my cable size problem is? Has anyone out there in the beautiful land of VDubs got a simple wiring diagram with the recommended sized cables for me to follow.

 

[nikmartin1]

From the options listed... I would probably take number 2 from Pete C list.... the only thing I would add is that the short cable used would be the maximum that would fit the Sargent.... and I would also use glue lined heatshrink... as it does seem to give it a) better stability... and also adds another level against moisture....

I suppose you could always send an email to the Sargent helpline/customer services and see what they suggest... as they maybe offer an additional item as you can't be the only one with this issue... surely......

Just spoke to one of the technical guys at Sergant. Not what I'd call the most forthcoming helpful person I've ever spoken to. Which is kind of weird, as everyone I've spoken to about anything to do with my T5.1 conversion has been really really friendly and incredibly helpful. My basic first question was regarding the ideal size of cable needed to go from the leisure battery to the main LB input of the Sergant. It felt like getting blood out of a stone. He wouldn't commit and said they don't usually advise people of what size cables we should use. I kind of got the idea he wanted us to work it out for ourselves. While I'm sure there are various different pieces of equipment we all want to install into our vans, 99.99999% of us only want initially the basics. Fridge, water pump, a few led lights and maybe a couple of usb sockets. But surely the most basic question that needs to be answered is what is the ideal cable size to link your leisure battery to the sergeant unit. When I said I felt my cable was too large to fit into the LB input. (a good high quality one the same as the one form my vehicle battery to the split relay), he suggested using 2 smaller cables to spread the load. Kind of makes sense. But, 1. why isn't that somewhere in the main instruction booklet? and 2. why don't they make life easier and put larger screw in socket on the back of the sergeant to negate the use of 2 cables? I can't be the only one that's got a bit confused with all this. And yes I know there are various different equations to work out just how many amps each item is gong to pull. I'm not wishing to get into that sort if depth. Just the basics. Phew, I'm gonna have a lie down in a darkened room.....my brain is fried lol.

 

[Boysan]

Its all a little worrying when you contact the manufacturer and they dont or aren't able to give you the help you want...after all its their product and you would think that whoever they put on the phones would at least be of a mind to either be honest and say they dont know the answer or better still take your number and say they will find out and call you back...but sadly today it seems that its more about taking someones money and making out that they are actually doing you a favour by selling you "their product".....

Moving on to the actual point raised....
The way to determine your actual usage and what you have in reserve is Ohms Law mate.... simple enough to add up and take away.... and in my experience its always better to give some tolerance ... ie upping the gauge of wire used...
Another thing that many forget is that cable has a certain defined bend... ie radius...keep the cabling as level as possible and no tight turns as this can cause issues with heat...
I dont actually know much about the unit you mention .... but many run on the principle that the topping up of the battery comes in when the input voltage is 240v ie you connect the mains and it starts to trickle charge the leisure battery.... which it sees as a "load" the better ones tend to measure this load and adjust the trickle charge accordingly...
Much of the Sargent range is used in the caravanning industry... in my view if you want the best of the best then marine grade equipement is the way to go... but there is nothing wrong with modern day caravan electrical fittings... which again in my experience.. caravans are built to a particluar budget and much of what I have seen as wiring... leaves a lot to be desired .... One thing for sure...your standards will be far better....

If all else fails then there is always the idea of getting an auto electrician to give it the once over... when its all in situ... as you can always leave out the fuses and just get him to cast his eye over the wiring... which most folk would be happy to do for a bit of gold passing via the palm... lol...