controller wire inputs too small

[manacabana]

every time I think I'm ready to start something else pops up...
i was looking at the controller and suddenly it dawned on me: these terminals are too small! there is no way I'll be able to fit 8 Gage wire in there!
there is nothing in the manual. so I wrote an email to Victron. Electronics. (I have a Victron 15/50 MPPT)

the guy said 11 Gage or 4mm2 is the max. my largest run is 5 feet each way but still. that would mean a 5% drop. I was trying to keep it under 2%.

anyway. all I can figure to do is install a switch for the battery as close to the controller as possible. do the wire from the battery to the switch with 4awg and then to the controller with 12 (I have never seen 11...)
then do the same for the panels. panels to switch with 10 into controller with 12.

is this good?

[bcroe]

You can splice on a short piece of smaller wire providing it is not overloaded. Some lugs
with smaller (or trimmed) ends can still take a large conductor.

The odd gauge wire is used for maximum space efficiency in winding transformers, etc.
Enamel insulation. Bruce Roe

[manacabana]

You can splice on a short piece of smaller wire providing it is not overloaded.

thanks Bruce. I had never given a thought to the 12/10 on the lugs and butt splices! I found some step down splices from 12/10 to 8 but they are very expensive. I'm going to get some experience with this first solar set up. later on I might decide I need a new controller... maureen

[littleharbor]

Maybe something like these crimp on pin ends would help.

Crimp on pin ends..jpg

[manacabana]

Maybe something like these crimp on pin ends would help.

Crimp on pin ends..jpg

oooo.cool. so these things would go into the controller's terminals like a quick disconnect? i like it. of course, the trouble is "Crimp The Ferrule Terminal With A Professional Crimping Tool."... I only got the Irwin vise grip multi tool. think I could crimp one of those ends on a 8awg wire only using a hammer and a screw driver?

[littleharbor]

I'm seeing these in 8 and 6 awg. sizes. I don't see any mention of using a professional crimping tool for them. Whatever crimping tool is used, you would need to get a good, tight crimp on them, that would go without saying tough. I just discovered these recently when a few were sent to me with some other stuff I ordered.

[manacabana]

Whatever crimping tool is used, you would need to get a good, tight crimp on them,

out of curiosity, what do you use to crimp larger Gage wire (8 and up)? the Irwin tool only does up to 10.

[littleharbor]

I have a hydraulic crimper with die sets for up to 4/0 cable.

[emartin00]

oooo.cool. so these things would go into the controller's terminals like a quick disconnect? i like it. of course, the trouble is "Crimp The Ferrule Terminal With A Professional Crimping Tool."... I only got the Irwin vise grip multi tool. think I could crimp one of those ends on a 8awg wire only using a hammer and a screw driver?

Those are ferrules. They don't make the wire any smaller. They are designed to apply to finely stranded wire that needs to be installed in a mechanical connector.
You would need something like this:

https://www.mouser.com/ProductDetail/TE-Connectivity-AMP/180599?qs=sGAEpiMZZMvz8LftK4jertpKTtcQzJqYMcV3l96pJAw%3d

[littleharbor]

Those are ferrules. They don't make the wire any smaller. They are designed to apply to finely stranded wire that needs to be installed in a mechanical connector.
You would need something like this:

https://www.mouser.com/ProductDetail/TE-Connectivity-AMP/180599?qs=sGAEpiMZZMvz8LftK4jertpKTtcQzJqYMcV3l96pJAw%3d

Exactly what you need.

[emartin00]

out of curiosity, what do you use to crimp larger Gage wire (8 and up)? the Irwin tool only does up to 10.

You can get small hand tools that will do up to #2, but they take a fair amount of strength. Once you get to larger sizes, you either need a long handled crimper or a hydraulic tool.

[manacabana]

You can get small hand tools that will do up to #2, but they take a fair amount of strength.

Ive been looking... all I've been able to find are metric crimping things that cost $40 and get mixed reviews. is that what you are talking about? I'm a small woman but I did build a cabin by myself using mostly hand tools : ) maybe my mechanic has the tools for the job.

[Sunking]

Ive been looking... all I've been able to find are metric crimping things that cost $40 and get mixed reviews..

A good crimper will cost several hundred to several thousand dollars. The real issue you have discovered is the Controller like many out there is not designed what it is claimed to do. Your controller does not have terminals large enough terminals to meet minimum code and UL requirements.

[manacabana]

A good crimper will cost several hundred to several thousand dollars.

right. I knew about that. I was wondering if he was talking about something else. some secret work around.

i guess I'll just work with what I got. that's why I started small. I'll put it together take measurements and learn from it. see how much I'm losing due to wiring etc and go from there. maybe I can find an electrician here in the middle of nowhere who can crimp some cables for me and then get a better controller if I have to.

thanks, dude.

[Mike90250]

You can get un listed hydraulic crimpers from fleabay @ $50 , but the dies won't fit your lugs exactly, you've never done this before and don't know what to look for, but in my book, it's likely a poor hydraulic crimp is going to be way better than a medium long handle crimp.