[RE-wrenches] Battery cable crimper

Thu May 1 07:27:45 PDT 2014

 I only use the Quick Cable Hex crimpers, yes there ARE different models but using the "industrial" models and rotating the crimp as stated in the directions, and using QC lugs I have never had a problem. I do ALOT of 2/0 & 4/0 cables. Page 69 of their catalog offers you selection of crimp tools & dies. I do not recommend the CUB. My $.02 
On May 1, 2014, at 9:12 AM, Solar wrote:

> From what I'm hearing I think may go with a hammer crimper. Being able to crimp in a box might be handy, but it sounds like the quality of the crimps produced by the  hammer crimper is where it's at. 
> 
> Maybe a hammer and a long handle?! 
> 
> Thanks!
> 
> 
> Jesse
> RE-Power 
> 
> Sent from my iPhone
> 
> On May 1, 2014, at 1:08 AM, Ray Walters <ray at solarray.com> wrote:
> 
>> Here's all the battery lug crimpers I tried over the years in order of the best to worst connections they produced:
>> <bdbagfhj.jpg>
>> Yes, believe it or not: the venerable Hammer crimper makes excellent connections.  Its also Cheap, but its Slow, cumbersome, and can't be used in a J box.
>> The V and indent connection with the thin wall lugs makes the ideal battery and DC connections.  They look just like the crimps from Outback, Trace, Midnite,etc.  I've cut them open on a band saw, and the fine strands are practically fused together into an almost solid cross section of copper with no voids, but no tearing of strands at the edges either.
>> This crimper goes out on most jobs, as it fits in the bottom of the tool box.
>> <fhibhicd.jpg>
>> The Greenlee indentor crimper makes the same V  crimp connection as the hammer crimper, but is faster, and can be used up in a j box.  More expensive, and adjuster readings can't be counted on.  I tighten the adjuster until I can just pull the handle down with putting some body weight into it, but not so much that I'm standing on it or straining the tool.  Depending on the cable and lug combination, the setting may be 2 sizes smaller with thin wall lugs.
>> Overall, this is what we use most of the time.  I found that this set in a drill vice makes a good bench crimper, when you need to do a batch of battery jumpers.
>> 
>> <fcafcjdi.jpg>
>> I used this one for many years, also a V crimper, but has different dies.  Crimp quality was not as good, as the dies tore into the lug some.  Also changing the dies took time, and we once lost one of the dies, and it took months to get a replacement.  Not adjustable for different lug and cable combos.
>> 
>> <bfdddceg.jpg>
>> The "UL" Hex type crimper that you will find at regular electrical supply houses.  Quite expensive, but I am not a fan.  The dies bend slightly under pressure and so the hex crimps are not aligned with each other.  The dies tear the lugs, leaving sharp edges that can tear heat shrink, and there is no adjustment available to account for different cable and lug combinations.  
>> We have  X flex from Cobra, MTW from Quick Cable, and some DLO from another supplier.  All are UL listed 4/0 and all somewhat different in diam. and how the strands crush.  I have had a connection failure with this tool, and cutting through a cross section of the lug was not as solid a crimp as the V type.  I removed this tool from our shop, to avoid mistakes.
>> I'm sure with regular Class B stranded THHN, and the heavy wall, color coded lugs, that this is a good tool, but for battery connections, it does not work as well with thin wall lugs.
>> Finally, I do not recommend the heavy wall, long barrel lugs on batteries.  The square lug end is just too big and thick, and can't bolt to battery terminals in some cases.  We have had to grind away a corner for instance to have the heavy wall lugs land on an battery Flag terminal.  
>> The heavy terminals some what negate the advantages of flex cable in the first place.
>> R.Ray Walters
>> CTO, Solarray, Inc
>> Nabcep Certified PV Installer, 
>> Licensed Master Electrician
>> Solar Design Engineer
>> 303 505-8760
>> On 4/30/2014 7:33 PM, Solar wrote:
>>> I'd love a battery crimper, but a little out of my price range. 
>>> 
>>> I think a hand crimper will do. 
>>> 
>>> Jesse
>>> 
>>> Sent from my iPhone
>>> 
>>> On Apr 30, 2014, at 1:42 PM, Jerry Shafer <jerrysgarage01 at gmail.com> wrote:
>>> 
>>>> hydraulic or long handle bog difference in price
>>>> 
>>>> On Apr 30, 2014 8:32 AM, "Solar" <dahlsolar at gmail.com> wrote:
>>>> Hello all,
>>>> 
>>>> I am looking for recommendations for a battery cable crimper.  I'd love to get one with the dies built in, but the ones I've looked at are only for non-fine strand wire.
>>>> 
>>>> Suggestions?
>>>> 
>>>> Thanks!
>>>> 
>>>> Jesse
>>>> 
>>>> 
>>>> 
>>>> 
>>>> 
>>>> 
>>>> Sent from my iPhone
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