Battery charger temperature sensor ...

[Scott T-Bird]

I clipped the oversize ring off the end of the supplied temperature sensor (Sterling Procharge) so that I could fit the wire through a small hole that I made to feed the wire to the battery. I didn't realize until I clipped the wire that it is actually a very small insulated cover over a pair of very light gauge wires. I didn't get a chance to see how the wires were crimped to the ring connector. Can I assume that they simply get joined together at the crimp for a new ring or is there some kind of trick to putting it back together properly?

 

[jibes138]

Scott, that is the thermocouple that measures the temperature of the battery. If you cut it off it will no longer work. You will probably need to try to find a replacement part unless you have enough wire to crimp them using a butt connector.

 

[Scott T-Bird]

Not enough wire off the discarded ring side ... Can't the connection be duplicated? The original is just a ring with what looks like a simple crimp. I would guess that both wires would simply be connected at the ends by virtue of the common attachment to the ring. The ring gets attached to just one battery terminal, so how would the pair of wires be functioning independently?
I'm sure I can get a replacement if necessary.

 

[Rich Stidger]

Scott- jibes138 is right. The wire you cut is actually a pair of wires that connect to a thermocouple. The thermocouple is crimped into the large ring that attaches to the battery post. Depending upon its temperature, it changes resistance. It measures the amount of heat at the terminal and the charger responds accordingly. If you cannot reconnect the two small wires then the only remedy is to purchase a new sensor.
EDITED: A thermocouple is a pair of dissimilar metals that produces a voltage that varies with temperature. I was thinking of a thermistor which varies in resistance with temperature.

 

[Scott T-Bird]

Just reading a little bit about thermocouples, it appears that they are simply ends of wire connected at the sensor, which appears to simply be a ring such as the one shown here.
http://thesensorconnection.com/cht-..._Sh_FNDTJ8i5vV3E3wNWJMvzbvMl7hOBoCRB0QAvD_BwE
It is just a pair of 22? awg stranded wires joined to the ring. I snipped the wire at the end of the ring, right where the heat shrink covers the connection. By the extremely thin profile (there was no bump) there does not appear to be any separate connecter inside that covering. The ring also does not appear to be any different than a standard crimped ring connection. Wouldn't it be feasible to simply twist the ends together and insert in a standard crimp connection?

 

[Maine Sail]

Scott,

There is a temp sensor epoxied into the ring terminal, not crimped. By cutting it that close you've essentially ruined it. Would have been far better to cut the phone connector end off and re-terminated that end... you'll need to get a replacement from ProMariner...

 

[Ken Cross]

A thermocouple is composed of dissimilar metal. as it is heated it produces a tiny voltage whose level is related to the temperature. Things that will matter if you are trying to recreate one include the area of contact, and method of connection as well as connection type. As an example wire types of alumel for one conductor and cromel for the other may require same type connectors to join them. It's actually an involved science. Way easier to buy a new one if you can.

Ken

 

[JohnShannon]

might be a thermistor instead. Easy to tell, measure the resistance of the wires hanging out of the ring terminal, thermistor likely to be 10k and will drop a bunch if you warm the terminal with your fingers. Thermocouple less than an ohm. If it is a thermistor you can reconnect and you should be good to go.

 

[Scott T-Bird]

Scott,

There is a temp sensor epoxied into the ring terminal, not crimped. By cutting it that close you've essentially ruined it. Would have been far better to cut the phone connector end off and re-terminated that end... you'll need to get a replacement from ProMariner...

Live & learn I seem to always choose the hard way! It looked so much like a standard ring connection that I didn't look closely at the composition of the wire. It wasn't until I clipped it that I thought "uh oh". They should put a little warning tag at that end for imbeciles like me and it also seems that the assembly of the temperature sensor is too technical for field adaptation!

 

[jibes138]

Looks like a replacement is 17 to 20 bucks depending on where you buy it. I just installed one myself and also wondered how that terminal could measure temperature since it just looks like a standard ring terminal. Think of a meat thermometer and how the sensor is in that little point you stick in the meat and how fast they respond. Pretty amazing all this science stuff.

 

[jssailem]

They should put a little warning tag at that end for imbeciles like me

Scott. That would be an interesting idea. Tags like on pillows, and plastic bags? "DO not remove under penalty of..." Maybe mattresses... I'm sure you could get in trouble there....

 

[Scott T-Bird]

I assembled a set of those LED puck lights underneath the cabinets at my step-sons house last Sunday and there was 3 sets of inane warning tags hanging off the wires on each component. Instructions nowadays have like 3 pages of warnings leading into assembly instructions. All I ask for is one little label where it would have made a difference!

 

[Gunni]

The warning is provided on page 12 of the installation instructions where your wife should have seen it...since men never read the instructions. It was her fault!

 

[Scott T-Bird]

It was her fault!

I like this thought but maybe I shouldn't bring it to her attention.

 

[jssailem]

That is a place not to go... Suck it up like a man. You can think she may have made a slight omission but never never say it out loud...

 

[Scott T-Bird]

Suck it up like a man.

I don't know ... maybe I should hitch up my pants and place the blame squarely where it belongs ... right in her lap where the instructions should have been!

 

[Gunni]

Just let her know you are disappointed that she didn't prevent your mistake but love is all about forgiveness.

 

[jssailem]

I love how a young guy like you is ready to live on the edge....
For me that would be...