Phil,
I tend to agree that soldering crimp connections is not a good idea. It
makes the connection stiff and concentrates flexing to a smaller area.
Now this might be pure Hog Wash but I do not think that a crimp is not as
"Air Tight" as solder. I did see a crimp fail near a farm silo system,
plenty of bad NO2 and sulfur compounds. (These were #14 AWG stranded wires.)
The wires were corroded and the terminal overheated.
I have recently been playing with some # 4AWG cables with crimped 3/8 inch
ring terminals. These are constructed from a large number of fine strands as
to leave the cable flexible. Something so large seems to defeat the ability
to apply the high pressures required to form cold welds. When you flex the
cable near the terminal you can see some of the fine strands move.
Does anyone have experience and/or vendor names for very large crimmpers?
Thanks,
Bob K
-----Original Message-----
From: TechNet [mailto:[log in to unmask]] On Behalf Of Phil Nutting
Sent: Tuesday, July 10, 2012 6:37 AM
To: [log in to unmask]
Subject: Re: [TN] Crimp/Solder Lugs for DLO 535 MCM Cable
If you want to introduce unreliability into your system, then by all means
solder the crimped connections.
Many years ago I fought this battle, and won, with the aid of a document
from Amp. I think Steve Gregory posted it on his Homestead web site.
The theory is that with a properly sized wire/crimp combination you form a
gas tight mechanical weld. Adding solder creates a stiff failure point
where the solder ends and the unsoldered wire begins.
The one exception we have is for Litz wire. This is wire comprised of many
small strands of enamel insulated wire that must be stripped to make a
connection. Chemical stripping is one solution, but the added problems of
removing 100% of the stripping chemical and chemical hazards make this a
non-preferred solution. Instead we tin the wire ends in a solder pot that
burns off all the enamel and nylon serve (thread "jacket"). And yes, we do
get failures with this method on the smaller gauge wires (26-34 gauge) if we
flex them too many times. Typically these wires are only used in inductors,
chokes or transformers where the wires are terminated and no longer see
flexing once terminated. For the larger 10 AWG Litz, once tinned, it might
as well be steel for the stiffness it develops.
Phil Nutting
Design for Manufacturing Engineer
Kaiser Systems, Inc.
-----Original Message-----
From: TechNet [mailto:[log in to unmask]] On Behalf Of Graham Collins
Sent: Tuesday, July 10, 2012 6:27 AM
To: [log in to unmask]
Subject: Re: [TN] Crimp/Solder Lugs for DLO 535 MCM Cable
Excellent article! In the sailboat world the myth of soldering crimped
connections is healthy and thriving, it drives me nuts. But that is what
you get with a large DIY crowd and some dockside "experts"...
Thanks Steve.
regards,
- Graham
-----Original Message-----
From: TechNet [mailto:[log in to unmask]] On Behalf Of Steve Gregory
Sent: Monday, July 09, 2012 7:47 PM
To: [log in to unmask]
Subject: Re: [TN] Crimp/Solder Lugs for DLO 535 MCM Cable
John,
After looking around a bit, you really shouldn't solder a crimped
connection, you could very well be compromising the crimp itself, and cause
more problems than if you just left the crimp alone (assuming it was a
proper crimp to begin with). Here's a article from Jim Dunbar a Product
Manager for Terminals and Splices, and Senior Product Engineer Tom
Michielutti of Tyco that spells it out:
http://www.newark.com/pdfs/techarticles/tyco/ET.pdf
Look down at the bottom of page 4...
Steve
-----Original Message-----
From: Steve Gregory
Sent: Monday, July 09, 2012 6:01 PM
To: [log in to unmask]
Subject: Re: [TN] Crimp/Solder Lugs for DLO 535 MCM Cable
John,
I always thought that you didn't solder a crimped connection. But if this is
a requirement, then probably the best way to go about this is to get
yourself an American Beauty...
An American Beauty Resistance soldering unit that is, a model 10577 ought to
do the trick:
https://www.americanbeautytools.com/site/models/rs/109/features
There's even a Youtube video of it in action:
https://www.youtube.com/watch?v=h7vNQki7UgQ&feature=relmfu
Steve
-----Original Message-----
From: John Anselmo
Sent: Monday, July 09, 2012 4:36 PM
To: [log in to unmask]
Subject: [TN] Crimp/Solder Lugs for DLO 535 MCM Cable
Ok, we need to solder the lugs (after crimping) for a 535MCM DLO Cable.
What's the easiest way to do this?
Thanks,
John
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