I'm in the process of wiring up my EG4 Indoor battery with the 12000xp, and I've hit a snag. I bought some crimpers to attach a ferrule to the battery-inverter connection, but no matter what I do, the ferrule keeps slipping off the fine-stranded 2/0 wire supplied by EG4. It feels like the wire might be compressing too much for my crimp die to actually create a secure indent. Has anyone else encountered this issue or have any tips?
3 Answers
You might want to try using a smaller size ferrule instead of stressing about it too much. Most of the time, the cables supplied are pretty reliable, but crimping can be tricky depending on the wire stranding.
You definitely want to check if your crimper creates a hexagonal crimp. If it doesn't, you might be having trouble because highly flexible cables require a specific kind of crimper to form a solid connection. Some crimpers are designed specifically for high flex cables, which is crucial. Also, remember that high flex cables require different sizes in lugs and dies than regular stranded cables.
By the way, I worked in power plants for over 40 years, so I've seen this issue quite a bit!
It sounds like your crimper might be designed for lugs rather than ferrules. Lugs are generally thicker and may not fit well with your setup. Have you checked if the 12k has bolt studs where you could attach lugs instead?
Thanks for the detailed info! The crimper I'm using does make a hexagonal crimp, but I still feel like it compresses the ferrule way too much. Maybe I really do need thicker lugs to get a solid fit with my high flex setup.