I have to give Jay big yay for the perfect answer. Solder loses any ability to create a useful joint when it liquifies, hence the need for some very solid mechanical joining means. The failure modes are truly bad with power involved.
Crimping to make gas-tight fused connection is the only acceptable joint. Preferably, a pin and socket connection which allows rotation of the wires is chosen to take stress off of the interface between the wire and crimp. Non-rotating connections eventually work harden and break the wire. Vibration and thermal cycling ramp this up. This might not be a big deal with EV charging connectors, but... If you DIY a poor crimp and try to mitigate using solder, the solder WILL wick up the wire stiffening it. This will be a potential failure point, but it is better than solder with no crimp or an in improper crimp. Don't take this lightly or you may burn down your home. I would try to find or rent a good crimper. The PV industry uses good DC rated wire connector systems. In CA you may be able to locate good tools and connectors easier than the rest of the country. On Apr 23, 2016 10:20 PM, "Jay Summet via EV" <ev@lists.evdl.org> wrote: > You need mechanical attachment, which crimping gives you. > > Soldering in addition to crimping may decrease your resistance, but also > risks wicking up the copper cable and making the cable susceptible to > breaking if flexed. (If the pin to cable connection is inside a connector > that prevents that area of the cable from flexing, this may not be a big > issue.) > > Jay > > On 04/23/2016 09:53 PM, Lawrence Rhodes via EV wrote: > >> There is a heated debate on Facebook as to weather it is acceptable to >> solder the J1772 pins to make your DIY cord. I think crimping or soldering >> will work. But at 14.4kw there might be issues with solder. I don't see >> the problem of heat at 6.6kw. Lawrence Rhodes >> _______________________________________________ >> UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub >> http://lists.evdl.org/listinfo.cgi/ev-evdl.org >> Read EVAngel's EV News at http://evdl.org/evln/ >> Please discuss EV drag racing at NEDRA ( >> http://groups.yahoo.com/group/NEDRA) >> >> _______________________________________________ > UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub > http://lists.evdl.org/listinfo.cgi/ev-evdl.org > Read EVAngel's EV News at http://evdl.org/evln/ > Please discuss EV drag racing at NEDRA ( > http://groups.yahoo.com/group/NEDRA) > > -------------- next part -------------- An HTML attachment was scrubbed... URL: <http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20160424/d6e08875/attachment.htm> _______________________________________________ UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub http://lists.evdl.org/listinfo.cgi/ev-evdl.org Read EVAngel's EV News at http://evdl.org/evln/ Please discuss EV drag racing at NEDRA (http://groups.yahoo.com/group/NEDRA)
