14 replies to this topic

[nicklouse]

Right two wires both labled as 25mm

With connectors just slide on.


Both connectors on one wire as they would not go on the other one as it is too big!



As you can see both connectors are labelled for the same area wire both wires are labelled as the same.
But the connectors are different diameters as are the wires.

What is going on? Or what don't I know?

Confused.

[dklawson]

There is probably a small difference in the strand count for each of the wires.  However, the copper bundles don't look that different to me.  You cannot judge a wire size by the insulating jacket diameter.

 

As for the ring terminals, the fit is not spelled out in an international standard.  As long as they can both crimp securely onto the copper bundle, that's all that matters.

[KernowCooper]

And thats why I buy my wire and crimp ends from the same manufacturer, see what Nicks got before, and yes some of the wire even though marked the same has different wire strand diameter

[nicklouse]

Insulation has never been considered.

It is just odd that I could not use the 8mmx25 connectors on one 25mm wire and the 10mmx25 are a real sloppy fit.

Sloppy fit it will be. Until crimped of cause.

[Spider]

The Short one with the M10 hole (I think) to me appears to be a solder lug, not a crimp lug.

[djdanmk]

We get this with crimp lugs all the time at work it depends on the make as to how well they fit over the cable and we end with what ever make the wholesalers send us. As already said as long as it crimps up nice and tight onto the cable then it should be fine.

[Spider]

 As already said as long as it crimps up nice and tight onto the cable then it should be fine.

 

Hmmm,,,, sorry, but they can be over-crimped too.

[Steve220]

The 2 ends you have that are square headed are solder lugs. Don't crimp them, they'll crack.

[nicklouse]

The 2 ends you have that are square headed are solder lugs. Don't crimp them, they'll crack.

just used for illustration.

 

as we know a circle with an area of 25mm square gives a diameter of 5.6mmish but here we have two wires that have different diameters (shown by them not fitting into both shoes.

 

I just find it odd that they cant make things the same.

[nicklouse]

thinking on. I guess the diameter of the individual threads would effect things. the finer they are the less the total diameter?

[Mini Manannán]

thinking on. I guess the diameter of the individual threads would effect things. the finer they are the less the total diameter?

Yes, they'd fit together with smaller gaps between strands

[djdanmk]

As already said as long as it crimps up nice and tight onto the cable then it should be fine.

 
Hmmm,,,, sorry, but they can be over-crimped too.

We use hydraulic crimping tools at work that release once the correct pressure has been applied so you can't over tighten the crimp

[tiger99]

Actually, the ONLY way of guaranteeing a reliable crimp, especially for high current applications like this, is to use a properly calibrated, and sadly, expensive, crimp tool, and for this size of wire they are often, but not necessarily, hydraulic. The dies used in the crimp tool must match the combination of terminal type and wire diameter being used.

 

No way is it worth buying a tool for just a few terminals. Best to get it crimped by an auto electrician with the correct equipment, and avoid failure or even fire.

[Spider]

thinking on. I guess the diameter of the individual threads would effect things. the finer they are the less the total diameter?

 

Actually, they go the other way, the finer and more strands, the bigger the OD ends up for the same copper CSA.

 

http://www.cabac.com...0010/al1000.pdf

[tiger99]

Moke Spider,

 

Very interesting! I have bookmarked that link for future reference. And just imagine the cost of all the tooling they are recommending. See how much crimping force they are recommending!

 

I think the article is suggesting that part of the difference is caused by the "lay" of the wires, i.e. whether they are just one straight, parallel or very mildly twisted bunch, or stranded in groups, which are then stranded together. For example, 7 strands is common, because 6 fit around 1 central wire neatly, and if you add another layer at twice the radius you get an extra 12, giving 19, so 19 strand wire is also very common. Another layer will add 18, giving 37 total, etc, But a large cable might be made from 7 or 19 groups of 7 or 19, so you might have 49, 133 or 361 strands. The air space within will differ, and is affected by how tightly the inner stranding is twisted. Then we get metric cables with 16 strands. I don't know how the 16 are supposed to be arranged, as that number doues not fit neatly around a central wire.

 

If you want to understand wire stranding, get lots of identical coins, say 1p, and arrange them on the table. Washers, or buttons, face down, will also do as long as they are all the same diameter. You will soon see what works.