Battery Case Wiring
12 Volt Battery Case with Anderson Powerpoles®
Richard Hagemeyer, VE3UNW
This article describes a battery case which has been outfitted with Anderson Powerpoles®
and a self-resetting fuse. It is a simple project with easy to obtain parts and can be put
together in an evening.
This list of parts required is as follows:
1 12 V Deep Discharge Battery
Marine batteries cost $90-$180
1 Vented Battery Box
Group 24 (CT:79-0312-2) or 28 (CT:79-0314-8)
1 Self-resetting fuse or circuit breaker
20 or 30 Amp $7-$20 (Canadian Tire)
1 Fuse holder
Not needed for circuit breaker (Canadian Tire)
6’ Heavy duty stranded wire
10 Anderson Powerpoles®
30 Amp connectors (EMRG)
Canadian Tire or Radio Shack
1 Heavy duty 5-way binding post
4 Ring connectors
Battery connection(Canadian Tire or Radio Shack)
6 Tie wraps
Solder
Hardware
The parts can be found at either Canadian Tire or Radio Shack. You might want to try
Princess Auto or Active Electronics as well. Use tie wraps inside to neaten up the wires;
after all, you’ll be showing your project to all sorts of fellow hams soon!
DESCRIPTION
The battery case as shown is a
group 24 (car size) marine deep
discharge battery. The case has 4
sets of powerpoles mounted,
although only 2 can be clearly seen
in the picture.
The case also features a heavy duty
binding post. Inside the case is a 2
foot wire with powerpoles direct
connected to the battery. I use this
mostly for charging. It really should
have a fuse on it, but none is
installed currently.
The previous picture with the binding post in
the center, is a case with the self-resetting
fuse. The case on the left has the binding
post offset from the center and uses a heavy
duty circuit breaker. The circuit breaker
mounting screws can be seen in the centerline.
EMRG Newsletter - November 2005
Page 1
Regular fuse in the holder with a self-resetting fuse in front. >
If the fuse option is chosen, you will have to bring the
connections together from the powerpoles and solder them
together. It is a lot of wire and will require a fair amount of
heat to solder. Afterwards, wrap electrical tape around
generously. Remember, what is in the box is out of site and a
poor job can be disastrous!
If a heavy-duty circuit breaker is chosen, ring terminals can
be used inside the box and bolted to the circuit breaker on
one side and the 5-way binding post on the other.
Inside view with fuse holder in upper middle
Inside view with circuit breaker in upper middle
CONSTRUCTION
Start by deciding on the connector layout for your box. The only downside I can see to my
choice is the fact that the connector faces up and could trap dirt and debris over time.
Use an electric drill with a sharp bit on slow speed to drill wire and mounting holes. Use the
template on the package as a guide to mount the binding posts. If using the circuit breaker,
you can use the device to mark the centers.
Solder about one foot of heavy duty wire to each of the four powerpole connectors. Pay
attention to polarity of your wire; at least be consistent.
Each of the powerpoles will need a larger hole for the wire feed and two smaller holes for
accept the plastic wire wrap. You may want to drill one and try out the mounting before
drilling all the holes. That way you can adjust bit size or placement as required. Mount the
binding post and if chosen, the circuit breaker. Finish up by mounting the remaining
powerpoles.
Trim the wires, but not too tight. The only wire that really needs to be a bit long is the wire(s)
from the battery to the top of the case. If it’s too short, you’ll swear every time you need to
take of the cover. The wires from the powerpoles to the binding post and circuit breaker can
be shorter. Make them too short and you’ll have difficulty getting them all together.
Dress the wires with ring connectors as appropriate and make the final connections. If you
are soldering really pay attention to polarity; it’s harder to fix!
EMRG Newsletter - November 2005
Page 2
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