[RE-wrenches] Battery Cable REvistied

Tue Nov 30 12:48:27 PST 2010

Vaseline will also flow into the cable strands, just like solder, coating
and protecting all the internal strands. Almost too hot to touch is plenty
hot enough to allow it to flow. Too hot and it burns.
Jim Duncan
  -----Original Message-----
  From: re-wrenches-bounces at lists.re-wrenches.org
[mailto:re-wrenches-bounces at lists.re-wrenches.org]On Behalf Of R Ray Walters
  Sent: Tuesday, November 30, 2010 1:54 PM
  To: RE-wrenches
  Subject: [Norton AntiSpam] Re: [RE-wrenches] Battery Cable REvistied

  We use the same inner melt heat shrink, I think. You don't know you have a
problem, until you cut that pretty heat shrink off 5 years later, and see
what is happening underneath.
  The reason we use the vaseline, is that it remains conductive, so we can
precoat the connectors before assembling and tightening. (Windy Dankoff
taught us that one)
  I would see the 3M coating as something to spray on after, but I would be
concerned about using it on contact surfaces before.
  I agree, heat can be an issue, so we use a high temp grease for
applications were the temp might get over 100 deg F.
  Maybe a combination might work best:  grease on the contact surfaces
before, and 3M spray outside after?

  R. Walters
  ray at solarray.com
  Solar Engineer

  On Nov 30, 2010, at 9:47 AM, Warren Lauzon wrote:

    We use the “inner melt” type of heat shrink and have had few problems
with it compared to the standard heat shrink. As far as Lead plated lugs, I
am not sure I see much advantage to them. Also as far as coatings go, most
Vaseline and other standard grease type are way too temperature sensitive,
and in hot weather they just melt away – and they are also great
dust/bug/dirt gatherers. 3M and others make a spray on coating that hardens
somewhat that we have found to be much better. From the 3M website “Scotch®
Insulating Sprays 1601 and 1602 are electrical-grade, fast-drying enamel
sealers and insulators in pressurized cans. Full Description »  These
sealers protect surfaces against weather, moisture, corrosion, oil, alkalies
and acids. The sprays can afford easy access to hard-to-reach spots. Use
Insulating Spray sealers to spray over insulation on wire and cable splices,
as a general-purpose sealer, or for touch-up insulation on motor windings
and frames. Sprays are available in clear, red or black.”

    The local Home Depot carries it here, also some electrical distributors.

    From: R Ray Walters
    Sent: Tuesday, November 30, 2010 9:26 AM
    To: RE-wrenches
    Subject: Re: [RE-wrenches] Battery Cable REvistied

    HI Mark;

    Where do you get the lead plated lugs? We used to special order tin
plated lugs from Del City, but they quit carrying them.
    I found that the grease or vaseline coating was the most important
issue, though. Tin plated lugs would corrode just like the unplated ones,
except they first would lose their plating.
    Lead plated lugs might just be the ticket, except you would still have
to keep the corrosion from creeping up under the heat shrink to the copper
cable.
    I've had cables with corrosion going up the cable strands for over 6"
past the lug. And yes we use heat shrink with the sealing adhesive inside;
the corrosion just travels right under it along the surface of the metal. I
actually found electrical tape seals better, it just doesn't look near as
good, so we still use heat shrink, and coat over the heat shrink with the
vaseline (or grease).

    R. Walters
    ray at solarray.com
    Solar Engineer

    On Nov 30, 2010, at 9:09 AM, Mark Frye wrote:

      I recently worked with a telecom specification that required lead
plated copper lugs on the battery side and I have been using the same on my
own systems for some time now.

      How important is it to use lead plated lugs on the battery side? Is
tin plated copper just as good so long as you coat well with grease etc.?

      Mark Frye
      Berkeley Solar Electric Systems
      303 Redbud Way
      Nevada City,  CA 95959
      (530) 401-8024
      www.berkeleysolar.com

--------------------------------------------------------------------------
      From: re-wrenches-bounces at lists.re-wrenches.org
[mailto:re-wrenches-bounces at lists.re-wrenches.org] On Behalf Of Glenn Burt
      Sent: Monday, November 29, 2010 6:03 PM
      To: 'RE-wrenches'
      Subject: Re: [RE-wrenches] Battery Cable REvistied

      Hi Ray,

      I have for my last 2 battery jobs used the Cobra X-Flex in 2/0 size
with MTW rating.

      At the battery end I have found the Thomas & Betts 54163-TB lugs,
available at my local Grainger store to be a good match both mechanically
and specification wise (also the correct hole size for M8 terminals in my
Concorde AGM’s).
      On the usual electrical equipment end, I use a Greaves Shoo-Pin
PT131FX20 as the appropriate reducer to a THHN stranding #2/0 size
(available through our local Graybar store, drop shipped to my office).
Because I am using a Sunny Island, of course nothing #2 fits… so I have two
Polaris style connectors in the trough below the SI where I switch from the
Shoo-Pins to four #1 THHN to go up into the SI batt terminals (two
conductors per pole).

      In fact, I am wrapping up one of these installs right now.

      Don’t know if this helps,

      -Glenn
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