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Open Roads Forum  >  Tech Issues

 > Best way to connect #6 wire to a #8 Screw Terminal?

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cruz-in

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Posted: 05/07/12 06:53am Link  |  Print  |  Notify Moderator

Hi All,

My solar charge controller has fairly small terminals (like #8 screws). I can only find appropiate sized crimp on connectors for up to #10 wire. Any thoughts on how to either use a #6 wire with a #8 screw terminal or to reduce my long #6 run to #10 for connection to the terminals?

Thanks

1995brave

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Posted: 05/07/12 07:00am Link  |  Print  |  Notify Moderator

Will any of these fit?

harold1946

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Posted: 05/07/12 07:37am Link  |  Print  |  Notify Moderator

Acording to the link provided the terminals will accept #6 wire.


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cruz-in

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Posted: 05/07/12 07:15am Link  |  Print  |  Notify Moderator

Yep however they only go up to #10 wire. The way the terminals are configured, a #8 spade connector is preferred

Oh by the way it is a Sunsaver MPPT 15 controller. FYI here is the link with pict:

Sunsaver MPPT Datasheet

cruz-in

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Posted: 05/07/12 07:51am Link  |  Print  |  Notify Moderator

harold1946 wrote:

Acording to the link provided the terminals will accept #6 wire.


Yes, I have chatted with Morningstar Tech Support about this. They acknowledged they know of no lug that will allow the attachment of anything bigger then #10 wire. They suggested (if using larger wire than #10) strip the wire, split the conductor in two, place half on each side of the terminal and tighten the terminal. I would rather use a lug as I think it is cleaner. Hence my question.

1995brave

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Posted: 05/07/12 08:40am Link  |  Print  |  Notify Moderator

How about one of these ?

smkettner

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Posted: 05/07/12 09:28am Link  |  Print  |  Notify Moderator

Closest I know is a lug for #6 wire #10 screw

Probably need to narrow the lug end to fit.

Otherwise use some of their #6 butt splice connectors to step down to #10. Fold the #10 over to get a better crimp.


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cruz-in

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Posted: 05/07/12 09:56am Link  |  Print  |  Notify Moderator

1995brave and smkettner,

Thanks for the links one of those might work. certainly closer than anything I have been able to find...

MEXICOWANDERER

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Posted: 05/07/12 12:21pm Link  |  Print  |  Notify Moderator

With a pair of good diagonal cutters, cut a slot in the tip of the lug to the #10 hole. Carefully squeeze the tips together as best as possible. Use a tiny file to customize the slot. Grind off or file the edges on the outside of your new "fork" terminal to fit into the slot of the controller. I grumble every time I have to do this. I have a bin of around 200 6AWG/#6 fork (spade) milspec terminals, but we have a small problem with logistics or I'd mail you some.

cruz-in

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Posted: 05/07/12 12:26pm Link  |  Print  |  Notify Moderator

mexbungalows,

thanks that is the approach I will take...

Appreciate the thought on mailing a few...darn logistics...LOL...

should be pretty easy to cut, squeeze, and file.

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