diy solar

diy solar

to crimp or not to crimp

carbon RV pilot

carbon RV pilot

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Joined
Dec 17, 2020
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im building a diy battery setup for my rv, ive already ordered 4 eve 280ah cells and the overkill solar 120a bms will recommends on his sight, once i get the cells from alibaba [if alls well] i plan to order 4 more to make an 8s 12v system so needless to say ill be changing this around from 4s to 8s at some point so for that fact i ordered bolt on type connectors which will allow expansion down the road, ive watched several vids and read threads on this forum about buying/wrestling with crimp tools and good crimps/bad crimps kind of comments and these bolt on seem easier/reusable and cheaper overall... am i missing something? is crimpimg that much better? im still going to use the bolt on stuff sincei already got most of my bolt on connectors and circuit breakers, i even ordered the bolt on bms for the same reason.
 

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not sure but i think i remember it saying it was solid brass which im sure is not as good a conductor as copper and was coated with zinc to prevent corrosion, im going to go into my purchases and see exactly
 
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lol i had it all wrong, it says copper with nickel plate the only issue i thought was sitting flat on terminals but a little grind here or there i thought these would look clean and easy to upgrade cells and reuse these
 
For the BMS and the breaker, it's fine. I would be hesitant to rely on it or expect it to carry sufficient current.

SCC terminals are screw-type, but they sandwich the wire ensuring large surface area contact. The round against round is not at all equivalent and provides an uneven clamping pressure.

Personally, I would crimp terminals to the wire instead of using those.
 
snoobler said:
For the BMS and the breaker, it's fine. I would be hesitant to rely on it or expect it to carry sufficient current.

SCC terminals are screw-type, but they sandwich the wire ensuring large surface area contact. The round against round is not at all equivalent and provides an uneven clamping pressure.

Personally, I would crimp terminals to the wire instead of using those.
Click to expand...
yes, i considered that and figured this system will never push more than 50amps or so but i may reconsider the few terminals on batt lugs and bms... thanks for the input!
MattiFin said:
Looks like car audio connectors. Not big fan, so much total junk out there.

Also note that amazon is filled with chinese junk crimp terminals.
For example https://www.amazon.com/Glarks-Appro...Assortment/dp/B07LBQ4DTX/ref=lp_306730011_1_7
Click to expand...
yes they are audio connectors which i thought would be fine since this rv system will be moderate aside from the occasional microwave spike the most theyll be pushing is 20-30amps. thanks
 
Aww! Darn, I just recieved the Glarks 105pc lug assortment too! It was a spur of the moment buy, I'll confess. $21.95! I should've known better. Although next to a solid copper lug, while not flared at the end, seemed like it was as thick as the copper one but weighed less. Both are awg6 X 5/16. Copper weighed 5gms Glarks weighed 4gm. Not sure about the whole "spy hole" on the other end of the Glarks either.
 

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MattiFin said:
Maybe these if you want screw fittings:

Single Wire Lugs, 1 Wire Termination per Lug on LugsDirect.com

Buy single wire single barrel terminal lugs. Allows 1500 kcmil to 14 AWG copper or aluminum wire, and are CSA certified and UL listed. Aluminum with tin plating. Made in the USA from domestic and imported parts
lugsdirect.com
Click to expand...
wow, these are what i remember seeing somewhere but couldnt find them anywhere online so i bought the ones i posted.... good eye!! i may still get a few of these, ill figure out how ill connect everything once i get my cells which should be in a few more weeks!
 
carbon RV pilot said:
im building a diy battery setup for my rv, ive already ordered 4 eve 280ah cells and the overkill solar 120a bms will recommends on his sight, once i get the cells from alibaba [if alls well] i plan to order 4 more to make an 8s 12v system so needless to say ill be changing this around from 4s to 8s at some point so for that fact i ordered bolt on type connectors which will allow expansion down the road, ive watched several vids and read threads on this forum about buying/wrestling with crimp tools and good crimps/bad crimps kind of comments and these bolt on seem easier/reusable and cheaper overall... am i missing something? is crimpimg that much better? im still going to use the bolt on stuff sincei already got most of my bolt on connectors and circuit breakers, i even ordered the bolt on bms for the same reason.
Click to expand...
Surely 8s will give you 24v, not 12v
 
Tyler702 said:
Aww! Darn, I just recieved the Glarks 105pc lug assortment too! It was a spur of the moment buy, I'll confess. $21.95! I should've known better. Although next to a solid copper lug, while not flared at the end, seemed like it was as thick as the copper one but weighed less. Both are awg6 X 5/16. Copper weighed 5gms Glarks weighed 4gm. Not sure about the whole "spy hole" on the other end of the Glarks either.
Click to expand...
That one looks actually little bit better than the ones I have(exactly same looking kit from alibaba)
I knew I got what I paid for when I got the package in my hands... so lightweight. :poop: Terminals weight like 1/2 of the European industrial terminals I'm used to...

"UL approved" claim is downright scam on those.

Amazon 1 star reviews are revealing:

Amazon.co.uk:Customer reviews: Glarks 125Pcs Marine Grade Heavy Duty Tinned Copper Wire Lugs Battery Cable Ends Eyelets SC Ring Terminal Connectors Assortment Kit

Find helpful customer reviews and review ratings for Glarks 125Pcs Marine Grade Heavy Duty Tinned Copper Wire Lugs Battery Cable Ends Eyelets SC Ring Terminal Connectors Assortment Kit at Amazon.com. Read honest and unbiased product reviews from our users.
www.amazon.co.uk
 
MattiFin said:
Maybe these if you want screw fittings:

Single Wire Lugs, 1 Wire Termination per Lug on LugsDirect.com

Buy single wire single barrel terminal lugs. Allows 1500 kcmil to 14 AWG copper or aluminum wire, and are CSA certified and UL listed. Aluminum with tin plating. Made in the USA from domestic and imported parts
lugsdirect.com
Click to expand...
Thanks for posting that. Gave me more to think about and was ultimately the final straw in reversing my decision from not getting crimpers. Those look great, then you start thinking about expansion, also having to mount them to bus bars, etc etc, yadda yadda, and your hardware requirements and complexity grows. The number of connection points that can potentially come loose grows. Originally I was thinking about buying cable with lugs, but that is a money pit over time. Best, I think, to have the tools. DIY also means do it yourself maintenance and expansion. Otherwise you’re just going to spend the money you save paying someone else to do the maintenance or expansion.

edit: here’s a discussion on various crimping tools:
Thread 'Temco Lug Crimping Tool'
https://diysolarforum.com/threads/temco-lug-crimping-tool.8683/
 
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carbon RV pilot said:
im building a diy battery setup for my rv, ive already ordered 4 eve 280ah cells and the overkill solar 120a bms will recommends on his sight, once i get the cells from alibaba [if alls well] i plan to order 4 more to make an 8s 12v system so needless to say ill be changing this around from 4s to 8s at some point so for that fact i ordered bolt on type connectors which will allow expansion down the road, ive watched several vids and read threads on this forum about buying/wrestling with crimp tools and good crimps/bad crimps kind of comments and these bolt on seem easier/reusable and cheaper overall... am i missing something? is crimpimg that much better? im still going to use the bolt on stuff sincei already got most of my bolt on connectors and circuit breakers, i even ordered the bolt on bms for the same reason.
Click to expand...
If those threaded terminals were available when I ordered my overkill bms I would have given them a try.
But then again I like mechanical lugs.
Big fan of these https://www.digikey.ca/short/4t4zhv

But not for a mobile application and that breaker looks like the cheap amazon junk.
I'm not trying to be mean, just don't want you to have a fire.

IMG_20210130_085249.jpg
 
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Don't Fear The Crimper! I had never crimped large lugs before and my experience crimping small ring terminals was rather disappointing. But every big cable lug I crimped came out perfect.

I didn't know the Overkill Solar BMS was available with bolt on terminals. If it had been available when I bought mine I would have considered it.

I'm not a fan of cable lugs with the "spy hole". The hole allows air in which can promote oxidation/corrosion. My crimped lugs with heat shrink tubing are air tight. I don't know this to be true, but I suspect that the ABYC standards do not allow for lugs with that hole.
 
MattiFin said:
Maybe these if you want screw fittings:

Single Wire Lugs, 1 Wire Termination per Lug on LugsDirect.com

Buy single wire single barrel terminal lugs. Allows 1500 kcmil to 14 AWG copper or aluminum wire, and are CSA certified and UL listed. Aluminum with tin plating. Made in the USA from domestic and imported parts
lugsdirect.com
Click to expand...

That type fitting is used in most all stationary electrical panels. But I have never seen one used in any automotive, boat, or RV... as in mobile application. And I am a motor head, Jeep, muscle car, boat, RV, DIY guy.

So anytime I see something that has never been done before, I ask myself... is that because it is such genius no else ever thought of it? Or is it a dumb idea, no one else would try?

If I was asking myself that question, on using screw lugs in a mobile application, I would say to myself... self, that probably falls on the dumb idea side.

But many folks frown upon those that talk to themselves. :oops: :LOL:
 
Mike Jordan said:
If I was asking myself that question, on using screw lugs in a mobile application, I would say to myself... self, that probably falls on the dumb idea side.

But many folks frown upon those that talk to themselves. :oops: :LOL:
Click to expand...

Seems legit.
thumb_up.gif
 
Mike Jordan said:
That type fitting is used in most all stationary electrical panels. But I have never seen one used in any automotive, boat, or RV... as in mobile application. And I am a motor head, Jeep, muscle car, boat, RV, DIY guy.

So anytime I see something that has never been done before, I ask myself... is that because it is such genius no else ever thought of it? Or is it a dumb idea, no one else would try?

If I was asking myself that question, on using screw lugs in a mobile application, I would say to myself... self, that probably falls on the dumb idea side.

But many folks frown upon those that talk to themselves. :oops: :LOL:
Click to expand...
Only weirdos frown on other people who talk to themselves... ??
 
Mike Jordan said:
That type fitting is used in most all stationary electrical panels. But I have never seen one used in any automotive, boat, or RV... as in mobile application. And I am a motor head, Jeep, muscle car, boat, RV, DIY guy.

So anytime I see something that has never been done before, I ask myself... is that because it is such genius no else ever thought of it? Or is it a dumb idea, no one else would try?

If I was asking myself that question, on using screw lugs in a mobile application, I would say to myself... self, that probably falls on the dumb idea side.

But many folks frown upon those that talk to themselves. :oops: :LOL:
Click to expand...
lol, that seems a bit extreme... the fact that you say things to yourself dont bother me, the fact that you answer yourself is another story all together! ive had several sports cars since the 90's always driving like a teen in a sports car with extensive stereo systems using these very type of connectors connecting capacitors/system batteries etc... feeding 3 4 sometimes 5 amps bordering Ludacris power and i cant remember even one time something failing or even loosening up! not as good is one thing but dumb idea? lol if you and yourself say so! thanks for the input!
 
Solder solder solder its fun its easy and if you use a big propane torch the colors in the flames are very pretty. Your crimps can be sloppy as heck. You can also solder those mechanical terminals. Why solder? It eliminates the possibility of corrosion between the terminal and wire. And done properly never comes apart.
Just dont use that lead free junk.
 
Good stuff on lugs. Welding suppliers have good experience with heavy DC current. Even good lugs at 250-300 amps will heat a cable termination up to the point that it will melt solder when doing steady high amp and high duty cycle. Most electrode holders are setscrew type and a while get too hot to hang onto with a 2/0 whip off a 3/0 cable.
Crimping does not melt. So welders supply would be my choice of where to look at terminals.
 
Ironman said:
Good stuff on lugs. Welding suppliers have good experience with heavy DC current. Even good lugs at 250-300 amps will heat a cable termination up to the point that it will melt solder when doing steady high amp and high duty cycle. Most electrode holders are setscrew type and a while get too hot to hang onto with a 2/0 whip off a 3/0 cable.
Crimping does not melt. So welders supply would be my choice of where to look at terminals.
Click to expand...
Okay so youre saying that because welding can heat up cables enough to melt solder, it shouldnt be used for solar battery storage.
Anyone using their solar systems for welding may find that helpful.
The rest of us, well here is what Trojan Battery says about it.
which states

"It is therefore highly recommended
that connectors not only be mechanically crimped
but also soldered to the cable’s end."

Go to the pdf and look at the infrared images. I will add if your battery terminals hit 370 degrees f, youve got bigger problems than melting solder.

The welding operations you speak of arent running that current through batteries.
 
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