Re: [EVDL] Modified K&W BC-20 questions (primary input leads)
Re: [EVDL] Modified K&W BC-20 questions (primary input leads)
When wire connections are burn like this, this is normally cause by a loose
connections and/or the terminals were connected up with out cleaning the a
dull tarnish surface that may be on the transformers connections which
causes a higher resistance.
It is best to use a torque wrench on these type of connections. Normally a
1/2 grade 5 bolt takes 50 ftlbs, a 3/8 at 35 ftlbs and a 5/16 at about 25
ftlbs if it's a straight through bolt with a nut. If it's a set screw type
of terminal, then your manual should tell you want the torque should be.
If this terminals are a solder on connection or the connection was compress
incorrectly by using only one point type crimp, then I would cut off these
terminal lugs and have new heavy duty tin plated copper terminal lugs crimp
on.
NAPA auto stores sell very heavy duty spec grade un-insulated wire terminals
that they keep in the back shelf's. I got 100 each 2/0 size wire terminals
for about $2.50 each. They may have two or three crimping guild lines that
is mark on the barrel. If there is two guild lines, then you crimp first
next to the cable and then the second crimp next to the bolt hole. If you
crimp next to the bolt hole section first, then the cable may push out some.
If it's has three guild lines, then crimp in the center guild line first,
the second by the wire and third at the bolt hole section.
The NAPA auto store, I go to can either crimp the wire terminals on the
cables which may be a hydraulic crimper, or you can rent a hand crimper from
them. Make sure you slip on the heavy duty heat shrink that has a sealent
in it first before you install the terminal.
It looks like there are un-plated thin copper wire terminals are use on your
battery links. You will have to watch these connections very closely, as
copper to lead will increase in turnish at the contact point which may
increase in resistance. After a while, bright copper will turn dark, to a
green color and then to something looking like white frosted coating. I
would give them a very good cleaning and torque them also.
A very good terminal coating I use, is that tool dip liquid compound make by
LocTite. It should be listed as acid proof and can be use on batteries.
Roland
----- Original Message -----
From: "Hunter Cook" <[email protected]>
To: "Electric Vehicle Discussion List" <[email protected]>
Sent: Thursday, October 04, 2007 9:58 AM
Subject: Re: [EVDL] Modified K&W BC-20 questions (primary input leads)
> Thanks for the advice, Roland.
>
> I don't think it's that serious...the transformer looks like it's fine
> to me. The burns are just on the input terminal, which I'm thinking I
> should be able to replace independent of the transformer. I don't know
> if it's glued on or what...it's on there tight. Figure I'll drop by
> radioshack today and see if they've got something similar.
>
> I put some pictures of it up in case you or anybody else wants to have a
> look: http://www.fivepointchilidog.com
>
> Thanks
>
> Hunter
>
>
When wire connections are burn like this, this is normally cause by a loose
connections and/or the terminals were connected up with out cleaning the a
dull tarnish surface that may be on the transformers connections which
causes a higher resistance.
It is best to use a torque wrench on these type of connections. Normally a
1/2 grade 5 bolt takes 50 ftlbs, a 3/8 at 35 ftlbs and a 5/16 at about 25
ftlbs if it's a straight through bolt with a nut. If it's a set screw type
of terminal, then your manual should tell you want the torque should be.
If this terminals are a solder on connection or the connection was compress
incorrectly by using only one point type crimp, then I would cut off these
terminal lugs and have new heavy duty tin plated copper terminal lugs crimp
on.
NAPA auto stores sell very heavy duty spec grade un-insulated wire terminals
that they keep in the back shelf's. I got 100 each 2/0 size wire terminals
for about $2.50 each. They may have two or three crimping guild lines that
is mark on the barrel. If there is two guild lines, then you crimp first
next to the cable and then the second crimp next to the bolt hole. If you
crimp next to the bolt hole section first, then the cable may push out some.
If it's has three guild lines, then crimp in the center guild line first,
the second by the wire and third at the bolt hole section.
The NAPA auto store, I go to can either crimp the wire terminals on the
cables which may be a hydraulic crimper, or you can rent a hand crimper from
them. Make sure you slip on the heavy duty heat shrink that has a sealent
in it first before you install the terminal.
It looks like there are un-plated thin copper wire terminals are use on your
battery links. You will have to watch these connections very closely, as
copper to lead will increase in turnish at the contact point which may
increase in resistance. After a while, bright copper will turn dark, to a
green color and then to something looking like white frosted coating. I
would give them a very good cleaning and torque them also.
A very good terminal coating I use, is that tool dip liquid compound make by
LocTite. It should be listed as acid proof and can be use on batteries.
Roland
----- Original Message -----
From: "Hunter Cook" <[email protected]>
To: "Electric Vehicle Discussion List" <[email protected]>
Sent: Thursday, October 04, 2007 9:58 AM
Subject: Re: [EVDL] Modified K&W BC-20 questions (primary input leads)
> Thanks for the advice, Roland.
>
> I don't think it's that serious...the transformer looks like it's fine
> to me. The burns are just on the input terminal, which I'm thinking I
> should be able to replace independent of the transformer. I don't know
> if it's glued on or what...it's on there tight. Figure I'll drop by
> radioshack today and see if they've got something similar.
>
> I put some pictures of it up in case you or anybody else wants to have a
> look: http://www.fivepointchilidog.com
>
> Thanks
>
> Hunter
>
>
