controller terminals too small

[Mauri Meere]

Hi all
If the controller terminals are too small to accept large battery cables is it permissable to bend back a couple of strands to make the connection or is there a better way?
Thanks
Mauri

[Joe Blake]

Are you suggesting using the couple of strands to connect to the controller? If so I should think the current would probably be too much for the strands and they would act like a fuse and melt.

Have you tried getting a set of wire cutters and cutting individual strands of copper from the battery cable where the insulation exposes the wire until it reaches a suitable diameter? Twist the copper strands then either form loop of wire or a straight cable then solder the strands together. Depends on the terminals of the controller.

[Mauri Meere]

I think we are on the same track. To reduce the cable diameter to fit into the terminal, you are suggesting cutting back a couple strands and I was going to bend them back and tape them or am I not understanding something?
I was also thinking of slicing a short piece of smaller diameter wire to the cable using a split-bolt kerney connector and insulating with tape.......but that just adds another connection that can go bad in the future.







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[Joe Blake]

Perhaps this might help.

http://www.achrnews.com/ext/resources/2013/08-2013/08-05-2013/S-HVACRTips-33-2.jpg

Alternatively you could crimp on a tag of suitable diameter.

https://encrypted-tbn0.gstatic.com/images?q=tbn:ANd9GcSGznYSflmofXjK0Zj6crsK8ZguamzTk 1sDUq0vZ4MrmOI2kHhcWA

[Mauri Meere]

Thanks for responses Joe.
I examined my dilemna more closely at my cabin over the weekend and I have some actual wire sizes. My system is small but my wires are oversized. The cables from the the panels are #4 awg and from the batteries #1 awg all going to the controller which has terminal openings that only accept #8 awg cable maximum. Somehow I have to reduce the cable ends to fit into the terminal openings.
Any suggestions?
Mauri

[Joe Blake]

Perhaps if you were to post a photograph it might be clearer.

Joe

[Terje Linseth]

1216

I use these types. This is for 3awg. They are Often made for car audio systems.

[Rob Beckers]

Mauri, while electrical code (and inspectors) frown upon it, many electricians do at times snap off a few strands to make a wire fit a tight connector. In your case, with greatly oversized wire, I wouldn't worry about it and just snap off enough strands until it fits.

As you mention, you can make a pig-tail of thinner wire and connect it to your large diameter wire. Over here the usual is a Marrette (wire nut, but everyone uses that brand name to indicate the type), as you say it adds another point of failure when snapping off a few strands does the job too.

-RoB-