Options for terminal ends

[peter2407]

Installing a new (to me) 20A sterling charger as a replacement for the current 30A (no pun intended) broken one, showed that the terminal fittings on the new one are considerably smaller than the old. After trying to keep the same teminal ends, I was concerned that they may end up touching, so tried smaller ones. This is where the problems started as using pliers in a tight space at odd angles, combined with the fact the the smaller ones are a snug fit for c.5/6 mm cable, means I cant get the crimp on tight enough. Any recommendations for where i can get ones that have a mechanical (screwed) means of connecting please?

 

[pvb]

Make up new cable tails with thinner cable, and properly crimped fittings. Then join them to the existing cables with terminal strip.

 

[peter2407]

Two responses:
A. Aaaarrrgghh why didnt i think of that as the new one came with tails that I cut off to "pack" the bigger older ones...
B. Although the new device had c.1.5 mm tails, isnt the perceived wisdom that bigger is better? And could i get a connector that reliably handle 1.5mm to the left and 6mm to the right?

Fair enough that the tail is small, but arent there going to be bigger loads further down the line?

 

[peter2407]

Bump

 

[pvb]

Two responses:
A. Aaaarrrgghh why didnt i think of that as the new one came with tails that I cut off to "pack" the bigger older ones...
B. Although the new device had c.1.5 mm tails, isnt the perceived wisdom that bigger is better? And could i get a connector that reliably handle 1.5mm to the left and 6mm to the right?

Fair enough that the tail is small, but arent there going to be bigger loads further down the line?

The purpose of having bigger cable is to minimise voltage drop. But voltage drop is dependent not only on cable diameter, but also the length. So using a smaller cable for 10-20cm in order to simplify connections isn't going to have a significantly adverse effect.

 

[nigelmercier]

The purpose of having bigger cable is to minimise voltage drop. But voltage drop is dependent not only on cable diameter, but also the length. So using a smaller cable for 10-20cm in order to simplify connections isn't going to have a significantly adverse effect.

I agree with what you say 100%. However, that doesn't make me happy to do it.

 

[pvb]

I agree with what you say 100%. However, that doesn't make me happy to do it.

But if the OP says his charger came with 1.5 mm tails (diam? Area?), and he's planning to use something a bit bigger, what's the problem?

 

[nigelmercier]

But if the OP says his charger came with 1.5 mm tails (diam? Area?), and he's planning to use something a bit bigger, what's the problem?

The problem is just my CDO. It's like OCD, but with the letters in the correct alphabetical order.

 

[colind3782]

The problem is just my CDO. It's like OCD, but with the letters in the correct alphabetical order.

+1

 

[skyflyer]

http://www.ybw.com/forums/showthrea...ical-connector-thick-cable-to-thin&highlight=

I raised a similar topic recently and the conclusion is that because the voltage drop along the line between charger and battery is a function of distance from the crater, it is perfectly acceptable to have a thinner cable for the first few inches of the run from the charger.

This can be achieved by thinning out strands of the existing cable and attaching a suitable crimp connector that will fit your charger terminals, or by running a small length of cable to a suitable junction box.

 

[LittleShip]

Whatever you decide to do use heat shrink to protect the terminals.

Tom

 

[nigelmercier]

Perhaps something like these:

http://cpc.farnell.com/pro-power/stdvb5-18/blade-contact-terminal-yellow/dp/CN11387

 

[Scubadoo]

or fork crimp terminal similar to this:

http://cpc.farnell.com/pro-power/stsv5-3-7/fork-crimp-terminals-yell-36a/dp/CN11420